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DDm

Publication No. US-DDm-IM-003 November 2003

Installation Manual PowerSafe DDM Modular Battery Systems clucier

Typewritten Text

BA-3

DDm

Installation Manual PowerSafe DDm Modular Battery Systems

IMPORTANT!

Read safety information first See Safety, Storage, Operating and Maintenance Manual

Publication No. US-DDm-IM-003 November 2003

Publication No. US-DDm-IM-003 November 2003 www.enersysinc.com

The installation manual is for reference only. To maximize safety and performance, read the accompanying Safety, Storage, Operating and Maintenance Manual thoroughly. It provides full instructions regarding safety, storage, operation and maintenance. Failure to observe the precautions as presented may result in injury or loss of life.

Copyright ©2003 by EnerSys Inc. All rights reserved.

This document is proprietary to EnerSys Inc. This document cannot be copied or reproduced in whole or in part, nor can its contents be revealed in any manner or to any person except to meet the purpose for which it was delivered, without the express written permission of EnerSys Inc.

Please check our website for literature updates.

www.enersysinc.com

Publication No. US-DDm-IM-003 Page i

GENERAL SAFETY INSTRUCTIONS

Warnings in this manual appear in any of three ways:

Danger

The danger symbol is a lightning bolt mark enclosed in a triangle. The danger symbol is used to indicate imminently hazardous situations, locations and conditions which, if not avoided, WILL result in death, serious injury and/or severe property damage.

Warning

The warning symbol is an exclamation mark in a triangle. The warning symbol is used to indicate potentially hazardous situations and conditions, which, if not avoided COULD result in serious injury or death.

Severe property damage COULD also occur.

Caution

The caution symbol is an exclamation mark enclosed in a triangle. The caution symbol is used to indicate potentially hazardous situations and conditions, which, if not avoided may result in injury. Equipment damage may also occur.

Other warning symbols may appear along with the Danger and Caution symbol and are used to specify special hazards. These warnings describe particular areas where special care and/or procedures are required in order to prevent serious injury and possible death:

Electrical warnings

The electrical warning symbol is a lightning bolt mark enclosed in a triangle. The electrical warning symbol is used to indicate high voltage locations and conditions, which may cause serious injury or death if the proper precautions are not observed.

Explosion warnings

The explosion warning symbol is an explosion mark enclosed in a triangle. The explosion warning symbol is used to indicate locations and conditions where molten, exploding parts may cause serious injury or death if the proper precautions are not observed.

Page ii Publication No. US-DDm-IM-003 www.enersysinc.com November 2003

IMPORTANT SAFETY INSTRUCTIONS

A battery can present a risk of electrical shock and high short circuit current.

The following precautions should be observed when working with batteries.

1. Verify that the Uninterruptible Power Supply (UPS) is off and that the power cord is disconnected from the power source.

2. Remove watches, rings or other metal objects.

3. Use tools with insulated handles to prevent inadvertent shorts.

4. Wear rubber gloves and boots.

5. Do not lay tools or metal parts on top of batteries.

6. Determine if the battery is inadvertently grounded. If inadvertently grounded, remove source of ground. Contact with any part of a grounded battery can result in electrical shock. The likelihood of such shock will be reduced if such grounds are removed during installation and maintenance.

7. Verify circuit polarities before making connections.

8. Disconnect charging source and load before connecting or disconnecting terminals.

9. Valve-regulated lead-acid (VRLA) batteries contain an explosive mixture of hydrogen gas. Do not smoke, cause a flame or spark in the immediate area of the batteries. This includes static electricity from the body.

10. Use proper lifting means when moving batteries and wear all appropriate safety clothing and equipment.

11. Do not dispose of lead acid batteries except through channels in accordance with local, state and federal regulations.

Publication No. US-DDm-IM-003 Page iii

SAVE THESE INSTRUCTIONS

This manual contains important instructions for PowerSafe DDm Lead-Acid Battery Systems that should be followed during the installation and maintenance of the battery system.

Only a qualified EnerSys Inc. service representative who is knowledgeable in batteries and the required precautions should perform servicing of the batteries. Keep unauthorized personnel away from batteries.

Misuse of this equipment could result in human injury and equipment damage. In no event will EnerSys be responsible or liable for either indirect or consequential damage or injury that may result from the use of this equipment.

Do not dispose of the batteries in a fire. The batteries may explode.

Do not open or mutilate the batteries. Released electrolyte is harmful to the eyes and skin and may also be toxic.

This unit contains sealed lead acid batteries. Lack of preventative maintenance could result in batteries exploding and emitting gasses and/or flame. An authorized, trained technician must perform annual preventative maintenance.

Failure to replace a battery before it becomes exhausted may cause the case to crack, possibly releasing electrolyte from inside the battery and resulting in secondary faults such as odor, smoke and fire.

Installation and servicing of batteries should be performed by personnel knowledgeable about batteries and the required precautions. Keep unauthorized personnel away from the batteries.

Proper maintenance to the battery system of this unit must be done by a qualified service technician. This is essential to the safety and reliability of your Uninterruptible Power Supply (UPS) system.

Page iv Publication No. US-DDm-IM-003

IMPORTANT!

Read safety information first See Safety, Storage, Operating and Maintenance Manual

Publication No. US-DDm-IM-003

TABLE OF CONTENTS

GENERAL SAFETY INSTRUCTIONS........................................................................................... i

GENERAL INFORMATION

RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES

SYSTEM LAYOUT

Anchor Spacing

FRAME ASSEMBLY AND INSTALLATION

Base Beams Vertical Channels Horizontal Channels Cell Support Shelves

BATTERY CELL INSTALLATION

Module Retainers Electrical Bonding Instructions

CONNECTIONS

Terminal Plates Inter-Cell Connectors Terminal Bars

INITIAL SYSTEM READINGS

SAFETY SHIELDS AND COVERS

Safety Shields Terminal Plate Covers

Page 2 Publication No. US-DDm-IM-003

GENERAL INFORMATION

PowerSafe DDm battery systems are modular units that can be installed in a SINGLE STACK (figure 1), a MULTI-STACK (figure 2), or a MULTI-STACK ZERO SEPARATION (Figure 3).

Systems are available in 24, 48 and other voltage configurations. These systems allow for assembly at remote locations.

See the ASSEMBLY DRAWING to determine the configuration for your installation.

Before installation: Verify items received versus Bill of Lading. Verify parts against system Bill of Materials.

SINGLE STACK

FIGURE 1

Publication No. US-DDm-IM-003 Page 3

MULTI-STACK ZERO SEPARATION

FIGURE 3

MULTI-STACK

FIGURE 2

Page 4 Publication No. US-DDm-IM-003

RECOMMENDED INSTALLATION EQUIPMENT AND SUPPLIES

Before working with the battery system, be sure that you have the proper protective clothing, safety equipment and insulated tools as specified in the Safety, Storage, Operating and Maintenance Manual for the VRLA Modular Battery Systems.

The following is a recommended list of equipment required for installation of a PowerSafe DDm Battery System.

TABLE 1

EQUIPMENT REQUIRED

CHECK IF ON HAND

Chalk Line Torpedo Level (Plastic) Torque Wrench (10-200 in-lbs) (SAE & Metric) Torque Wrench (50-100 ft-lbs) (SAE & Metric) Floor Anchors (User-supplied per battery system) Floor Shims (User-supplied) Drive Ratchet Wrench with Minimum 3” Extension (SAE & Metric) Box Wrenches (SAE & Metric) Screwdrivers Wipes, Paper or Cloth Stiff Bristle Nonmetallic Brush/Pad Tape Measure (Nonmetallic) Safety Equipment and Clothing Small Paintbrush Standard Allen Wrench Set

Be sure you have all the proper protective clothing, safety tools, and equipment on hand before starting the installation.

Publication No. US-DDm-IM-003 Page 5

SYSTEM LAYOUT

Before installing the battery system, lay out available floor space including aisles for installation, maintenance and possible cell replacement. Consult the local installation considerations as determined in Section 5 of the Safety, Storage, Operating and Maintenance Manual for the VRLA Modular Battery Systems. Recommended clearance between these racks and any objects (including walls and equipment) is 4 inches (102 mm).

1. Layout the system position for either a

SINGLE-STACK (Figure 4), a MULTI- STACK (Figure 5), or MULTI-STACK WITH ZERO SEPARATION (Figures 6, 7 & 8) configuration with the dimensions defined in Table 2.

2. Locate the position of the floor anchors using the frame base beams.

3. Mark floor with the position of the floor anchors.

“L”

FRONT

L

L

D

D = DISTANCE BETWEEN BASES (VARIABLE)

MULTI-STACK

FIGURE 5

M

DDm50 MULTI-STACK

WITH ZERO SEPARATION

FIGURE 6

W= DDm85 = 17.46 DDm100 = 20.47

W 7.67

DDm85/100 MULTI-STACK

FIGURE 7

19.81

Dm125 MULTI-STACK

FIGURE 8

NOTE:

• Floor anchoring is REQUIRED for all installations.

• Allow sufficient clearance between adjacent walls or equipment for proper installation of anchors. Please check your local codes for clearances required.

• Floor anchor design (including, but not limited to size, quantity, and capacity) and installation are the responsibility of the user/installer.

• Follow the user’s design and the manufacturer’s instructions.

10.75

SINGLE-STACK

FIGURE 4

Page 6 Publication No. US-DDm-IM-003

Anchor Spacing

TABLE 2

Base Beam Anchor Spacing

Cell Model 2 Cells Wide 3 Cells Wide 4 Cells Wide 6 Cells Wide Multi-Stack w/ zero spacing L (in) L (cm) L (in) L (cm) L (in) L (cm) L (in) L (cm) M (in) M (cm)

50-09 9.04 23.0 N/A N/A 16.52 42.0 24.01 61.0 L+0.89 L+2.3 50-13 12.04 30.6 N/A N/A 22.52 57.2 33.01 83.8 L+0.89 L+2.3 50-17 15.49 39.3 22.48 57.1 29.26 74.3 43.17 109.7 L+0.89 L+2.3 85-13 12.04 30.6 N/A N/A 22.52 57.2 33.01 83.8 L-2.94 L-7.5 85-15 13.54 34.4 N/A N/A 25.52 64.8 37.51 95.3 L-2.94 L-7.5 85-21 18.48 46.9 26.93 68.4 35.26 89.6 53.71 136.4 L-2.94 L-7.5 85-25 21.48 54.6 31.43 79.8 41.26 104.8 62.68 159.2 L-2.94 L-7.5 85-27 22.98 58.4 33.69 85.6 44.27 112.4 67.22 170.7 L-2.94 L-7.5 85-33 27.48 69.8 40.43 102.7 53.26 135.3 80.71 205.0 L-2.94 L-7.5 100-21 18.48 46.9 26.93 68.4 35.26 89.6 53.71 136.4 L-2.94 L-7.5 100-25 21.48 54.6 31.43 79.8 41.26 104.8 62.68 159.2 L-2.94 L-7.5 100-27 22.98 58.4 33.69 85.6 44.27 112.4 67.22 170.7 L-2.94 L-7.5 100-33 27.48 69.8 40.43 102.7 53.26 135.3 80.71 205.0 L-2.94 L-7.5 125-25 22.09 56.1 31.88 81.0 41.98 106.6 63.29 160.8 L-4.24 L-10.8 125-27 23.59 59.9 34.14 86.7 44.98 114.2 67.83 172.3 L-4.24 L-10.8 125-33 28.09 71.3 40.88 103.8 53.98 137.1 81.32 206.6 L-4.24 L-10.8

EXAMPLE:

If you are installing a DDm85 MULTI-STACK WITH ZERO SEPARATION and you have 21 plates/cell, 4 cells wide.

M (inches) = L (in) - 2.94” 35.26” - 2.94” = 32.32”

M (cm) = L (cm) - 7.5 cm

89.6 cm - 7.5 cm = 82.1 cm

Publication No. US-DDm-IM-003 Page 7

FRAME ASSEMBLY AND

INSTALLATION

To assemble and install the frame for the PowerSafe DDm battery system, follow the procedure below using the system layout determined in the “System Layout” section.

Base Beams

1. LEVEL with customer-supplied floor shims, and anchor in place. Do NOT torque anchor bolts until frame assembly is complete.

2. Install ALL base beams before continuing.

Vertical Channels

1. Insert vertical channels into base beams.

See Figure 9.

2. Bolt vertical channels to base beams. Refer to below list for hardware order and Figure 10:

• Serrated Hex Bolt (M10x1.5 –

100mm),

• Rack Frame,

• External Tooth Washer,

• Flat Washer,

• Lock Washer,

• Hex Nut

3. Torque all connections (except anchor bolts) to 40 ft-lbs.

INSTALL VERTICALS

FIGURE 9

VERTICAL CHANNEL TO BASE

BEAM HARDWARE DETAIL

FIGURE 10

Page 8 Publication No. US-DDm-IM-003

Horizontal Channels

Starting at the bottom of the REAR verticals:

1. Insert REAR horizontal channels into the vertical channels. Center the horizontals between the verticals. See Figures 11a & b.

2. Bolt horizontal channels to vertical channels.

Refer to below list for hardware order and Figure 12:

The bottom two horizontals require full thread longer bolts at the vertical channel.

Bottom horizontal:

– Serrated Hex Bolt(M10x1.5 – 100mm

Full Threads),

– Rack Frame,

– External Tooth Washer,

– Flat Washer,

– Lock Washer,

– Hex Nut Second from bottom horizontal:

– Serrated Hex Bolt (M10x1.5 – 75mm

– External Tooth Washer,

– Flat Washer,

– Lock Washer,

– Hex Nut All other horizontals:

– Serrated Hex Bolt (M10x1.5 – 25mm)

3. Finger-tighten connections.

4. Install ALL REAR horizontals before continuing.

INSTALL REAR HORIZONTAL CHANNELS

FIGURE 11A

INSTALL REAR HORIZONTAL CHANNELS

FIGURE 11B

REAR HORIZONTAL CHANNEL HARDWARE DETAIL

FIGURE 12

There may be two types of horizontal channels with your shipment:

1) Rear – have four weld nuts

2) Front – have more than four weld nuts

The front horizontals are universal and, in most configurations, are substituted for the rear horizontals.

Front horizontals are to be installed with the flange positioned with the holes facing up.

Publication No. US-DDm-IM-003 Page 9

Starting at the bottom of the FRONT verticals:

1. Insert FRONT horizontal channels into the vertical channels. Center the horizontals between the verticals. See figures 13A & 13B.

2. Bolt horizontal channels to vertical channels.

Refer to below list for hardware order and Figure 14.

The bottom two horizontals require full thread longer bolts at the vertical channel.

Bottom horizontal:

– Serrated Hex Bolt (M10x1.5 – 100mm

– External Tooth Washer,

– Flat Washer,

– Lock Washer,

– Hex Nut

Second from bottom horizontal:

– Serrated Hex Bolt (M10x1.5 – 75mm Full Threads),

– Rack Frame,

– External Tooth Washer,

– Flat Washer,

– Lock Washer,

– Hex Nut

All other horizontals:

– Serrated Hex Bolt (M10x1.5 – 25mm)

3. Finger-tighten connections.

4. Install ALL FRONT horizontals before continuing.

INSTALL FRONT HORIZONTAL

CHANNELS

FIGURE 13A

INSTALL FRONT HORIZONTAL

CHANNELS

FIGURE 13B

REAR HORIZONTAL CHANNEL HARDWARE

DETAIL

FIGURE 14

Page 10 Publication No. US-DDm-IM-003

Cell Support Shelves

Starting at the bottom of the rack:

1. Place shelves over FRONT and REAR horizontals. See Figure 15.

2. Align holes of shelf with holes of horizontal channels. Bolt the shelf to the REAR horizontal using (2) M10x1.5 – 25mm Serrated Hex Bolts in the two OUTSIDE holes of the shelf. See Figure 16.

3. Torque these bolts to 20 ft-lbs.

4. After ALL shelves for the rack are in place, position the vertical channels so that the front and rear horizontals fit tightly against the shelves. See Figure 17.

5. Torque ALL bolts connecting the horizontals to the verticals to 20 ft-lbs.

6. If you are installing a MULTI-STACK WITH ZERO SEPARATION system, repeat Procedures 1 through 5 until all shelves are installed.

7. Torque all anchor bolts according to system design and manufacturer’s recommendations.

INSTALL BOTTOM CELL

SUPPORT SHELF

FIGURE 15

CELL SUPPORT SHELF

REAR HARDWARE DETAIL

FIGURE 16

INSTALL CELL SUPPORT

SHELVES

FIGURE 17

MULTI-STACK WITH ZERO

SEPARATION systems are fastened together at the top front and top rear with a tie bar.

Publication No. US-DDm-IM-003 Page 11

USE CAUTION WHEN HANDLING THE

DDm MODULES After a cell has been inserted into a module at the factory, a loose fit could develop because of recombination. The cell could slip very easily from the module if the module/cell is turned so that the open end of the module is lower than the closed end of the module.

Serious personal injury could result if the cell slides unintentionally from the module. Keep shipping/installation retainer in place until modules are safely positioned on the shelves.

BATTERY CELL INSTALLATION

DDm battery cells are designed for shipment and use in steel modules.

1. BEFORE installing the cells, check the voltages. The minimum acceptable cell voltage is 2.05 vpc.

If a cell has a voltage below 2.05 vpc, call your nearest EnerSys sales/service representative for resolution, or call the corporate office number listed on the back of this manual and ask for EnerSys Integrated Systems & Services.

2. Inspect each terminal for visual signs of mechanical defects.

If terminals are acceptable:

3. Place the FIRST DDm module onto the

LOWEST EMPTY shelf, with the terminals toward the front. See Figure 18.

INSTALL FIRST MODULE

FIGURE 18

INSTALL SECOND MODULE

FIGURE 19

INSTALL MODULES

FIGURE 20

Report any defects to your nearest EnerSys sales/service representative for resolution, or call the corporate office number listed on the back of this manual and ask for EnerSys Integrated Systems & Services.

Page 12 Publication No. US-DDm-IM-003

4. Slide the module back into a safe position.

Remove the shipping retainer.

5. Slide module completely into position so the lip of the module touches the front of the shelf.

6. Place another cell onto the shelf next to the previously placed battery sleeve. Refer to the Assembly Drawing for the cell polarity configuration. See Figure 19.

7. Install remaining cells working from the lower shelves to the higher shelves. See Figures 20 and 21.

Module Retainers

1. For each battery module, install retainer plates and spacers as required, using a M10x1.5 – 25mm Serrated Hex Bolt. See Figure 22.

2. Torque to 20 ft-lbs.

Electrical Bonding Instructions

1. For each battery module, install (1) M6 Self-

Tapping Screw through front lip of the battery module into the shelf/horizontal channel. See Figure 23.

2. For each retainer spacer, install (1) M6 Self-

Tapping Screw through the spacer into the shelf/horizontal channel. See Figure 23.

INSTALL BONDING SCREWS

FIGURE 23

The top row of the rack requires spacers to be installed behind the upper lip of the battery modules. This spacer is fastened into place with the retainer and retainer bolt.

The larger modules are too heavy to lift onto the shelves manually. To avoid personal injury use appropriate lifting devices when lifting modules onto the shelves.

INSTALL MODULES

FIGURE 21

INSTALL RETAINERS

FIGURE 22

Publication No. US-DDm-IM-003 Page 13

CONNECTIONS

The cells are now positioned and ready to be connected. The cells must be connected according to the polarities on the ASSEMBLY DRAWING and the following instructions.

Before preparing and making connections, heat NO-OX-ID grease in hot water as necessary to soften for application with a paintbrush.

Terminal Plates

Terminal plates are provided with the battery system to provide a system connections point.

All system connections must be made to the terminal plate and NEVER to the cell terminal.

Top termination is standard, side termination is optional.

1. Clean the terminal plate electrical contact areas with a stiff-bristle nonmetallic brush/pad until the lead-plated surface is bright. Be careful not to remove the lead plating with excessive brushing.

2. Apply a light coat of heated NO-OX-ID grease to the terminal plate electrical contact area with a small paintbrush.

3. Assemble and install the terminal plate assembly finger-tight as shown in Figure 24 and 24A.

4. Check for alignment with cell terminal.

5. Torque all bolts to 15 ft-lbs.

INSTALL TERMINAL PLATES

FIGURE 24

TERMINAL PLATE INSTALLATION DETAIL

FIGURE 24A

Page 14 Publication No. US-DDm-IM-003

Inter-Cell Connectors

The connections are made by bolting the supplied lead-plated copper inter-cell and inter-module connectors to the cell posts of opposite polarity on adjacent cells. See ASSEMBLY DRAWING for details.

1. Clean the contact surface of the inter-cell connector using a stiff-bristle nonmetallic brush/pad. Be careful not to remove the lead plating with excessive brushing.

2. Apply a light coat of heated NO-OX-ID grease to the contact surface of the inter-cell connector and terminal post with a small paintbrush.

3. Bolt all inter-cell connectors according to the ASSEMBLY DRAWING. Assemble as the example shown in Figure 25 and below list:

• Bolt (M8)

• Lock Washer

• Flat Washer

• Inter-cell Connector

• Battery Post

4. Secure all connections finger-tight to allow for some adjustment of position.

5. After all connections are completed, torque to 88 in-lbs.

6. Apply a light coat of heated NO-OX-ID grease to the bolted connection with a small paintbrush.

INSTALL INTERCELL

CONNECTORS

FIGURE 25

Stamped flat washers may have one sharp edge. Install the washer with the sharp edge away from the lead-plated copper inter-cell connector to avoid damaging the lead plating.

Inter-cell connections vary in length depending on the type of connection (cell-to-cell, module-to-module, etc.) and/or stack configuration.

Publication No. US-DDm-IM-003 Page 15

Terminal Bars

Terminal bars are supplied with the battery system to provide a cell terminal-to-terminal plate connection.

1. Inspect the system to be assured that all cells are connected correctly – POSITIVE to NEGATIVE and according to the

ASSEMBLY DRAWING.

2. Clean the terminal bar contact area with a stiff-bristle nonmetallic brush/pad until the lead-plated surface is bright. Be careful not to remove the lead plating with excessive brushing.

3. Apply a light coat of heated NO-OX-ID grease to the terminal bar contact area with a small paintbrush.

4. Install terminal bar as shown in Figure 26.

5. Torque bolts to 88 in-lbs.

6. Apply a light coat of heated NO-OX-ID grease to the bolted connections with a small paintbrush.

INSTALL TERMINAL BARS

FIGURE 26

Page 16 Publication No. US-DDm-IM-003

INITIAL SYSTEM READINGS

Measure the DC system voltage across the system terminals. Voltage should equal approximately 2.15 times the number of cells in the system (See Table 3).

If the voltage is lower than 2.15 times the number of cells in the system, inspect the system to be assured that all cells are connected correctly — POSITIVE to NEGATIVE and according to the ASSEMBLY DRAWING.

TABLE 3

APPROXIMATE VOLTAGE

Number of Cells (2.15 x number of cells) 12 25.8 24 51.6

If the voltage is persistently lower than 2.15 times the number of cells in the system, contact your EnerSys sales/service representative, or call the corporate office number listed on the back of this manual and ask for EnerSys Integrated Systems & Services.

Make a copy of the Battery Maintenance Report found in the Safety, Storage, Operating and Maintenance Manual.

Measure and record the connection resistance of “CELL to CELL” and “CELL to TERMINAL” on the copy of the report.

Connections made to a battery for tapping a certain group of cells to provide a voltage other than the total battery voltage is NOT recommended and can VOID THE WARRANTY. It can affect the serviceability of the battery. Tapping results in an imbalance of the system during charging and discharging and results in unsatisfactory operation.

Publication No. US-DDm-IM-003 Page 17

STANDOFF

OPTIONAL

SAFETY SHIELDS AND COVERS

Safety shields and covers are provided to help prevent accidental contact with connections after installation and during operations. Safety shields and covers should remain in place at all times during normal operation of the system.

Terminal plate covers are provided as necessary to prevent accidental contact with the “live” terminal plate. Safety shields are designed to be removed for service or maintenance.

Safety Shields

1. Install ALL safety shield support posts into horizontals as shown in Figure 27.

2. Starting with bottom row, hang safety shields on support posts as shown in Figure 28.

Terminal Plate Covers

1. Connect load to the battery terminal.

2. Install terminal plate covers as shown in

Figure 29.

INSTALL SUPPORT POSTS

FIGURE 27

INSTALL SAFETY SHIELDS

FIGURE 28

INSTALL TERMINAL PLATE COVER

FIGURE 29

The bottom of each safety shield will overlap, on the outside, the top of the shield below it.

Page 18 Publication No. US-DDm-IM-003

NOTES

PRECAUTIONS*

1. Do Not bring any heat or flame source near battery.

2. Do Not remove pressure relief valves.

3. Do Not lift any cells by the terminal posts.

4. Do Not tamper with seal nuts on the cell post.

5. Do Not remove lead coating from post or connectors and expose any bare copper.

6. Do Not allow cell temperature to exceed 105oF during charging.

7. Do Not clean cell with anything other than water/bicarbonate of soda.

8. Do Not over torque connections.

9. Do Not store PowerSafe DDm type batteries for over six months without charge, at normal temperatures.

* These are only a few of the precautions. Please read all accompanying literature thoroughly for specific safety and installation information.

When ordering new batteries, also remember to properly recycle your old lead batteries. Federal and state regulations require lead-acid batteries be recycled.

EnerSys’ nationwide service organization can arrange pickup, transportation to and recycling at any one of our company affiliated smelters. Call 1-800-972-7372 for more information.

EnerSys Inc. EnerSys EMEA P.O. Box 14145 Brussels, Belgium Reading, PA 19612-4145 Tel: +32 (0)2 247 94 47 USA EnerSys Asia Tel: +1-610-208-1991 Guangdong, China +1-800-538-3627 Tel: +86 755 2689 3639 www.enersysinc.com

Represented by:

P ub lic at io n

N o.

U S

-D D m

-IM

-0

N ov em be r 2

USE EDGE OF MODULE

WHEN POSITIONING BATTERY

Please check our website for literature updates.

DO NOT PUSH ON CENTER

TO POSITION BATTERY

Table of Contents

Safety Instructions

General Information

Recommended Installation Equipment and Supplies

System Layout

Anchor Spacing

Frame Assembly and Installation

Base Beams

Vertical Channels

Horizontal Channels

Cell Support Shelves

Battery Cell Installation

Module Retainers

Electrical Bonding Instructions

Connections

Terminal Plates

Inter-Cell Connectors

Terminal Bars

Initial System Readings

Safety Shields and Covers

Safety Shields

Terminal Plate Covers

AT30 SERIES

Operating and Service Instructions

MICROPROCESSOR-CONTROLLED

FLOAT BATTERY CHARGER

THREE PHASE INPUT

(25 - 1,000 Adc)

JA5011-03

http://www.hindlepowerinc.com/� clucier

Typewritten Text

BC-101 & BC-102

HOW TO READ THE AT30 MODEL NUMBER

The AT30 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.

AT30

A B C D E F G H J K L M N P

Follow the chart below to determine the configuration of the AT30.

DESCRIPTION CODE FEATURE DESCRIPTION CODE FEATURE

A SERIES AT30 AT30 BATTERY CHARGER S STANDARD

012 12 Vdc M MEDIUM AIC 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

CODE FEATURE CODE FEATURE

G AC FUSES

(200 kAIC) X NOT SUPPLIED

025 25 Adc 200 200 Adc S STANDARD 030 30 Adc 250 250 Adc M MEDIUM AIC 040 40 Adc 300 300 Adc H HIGH AIC 050 50 Adc 400 400 Adc

H

DC CIRCUIT

BREAKER

RATING

(SEE TABLE)

0 NO DC BREAKER

075 75 Adc 500 500 Adc F SUPPLIED 100 100 Adc 600 600 Adc

J DC FUSES

(20 kAIC) X NOT SUPPLIED

125 125 Adc 800 800 Adc

C

NOMINAL

DC OUTPUT

CURRENT

150 150 Adc 1K0 1,000 Adc A SUPPLIED

U UNFILTERED

K AUX ALARM

RELAY BOARD X NOT SUPPLIED

F FILTERED (STANDARD) G SUPPLIED D DC OUTPUT

FILTERING

E BATT ELIMINATOR FILTER

L COPPER

GROUND BUS X NOT SUPPLIED

208 208 Vac 60 Hz L SUPPLIED 240 240 Vac 60 Hz

M LIGHTNING

ARRESTOR X NOT SUPPLIED

480 480 Vac 60 Hz 600 550-600 Vac 60 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 HIGH AIC 65,000 AIC 20,000 AIC

* Contact your sales representative 500-600 Vac 60Hz circuit breaker AIC ratings.

NOTICE .

The factory-configured model number printed on the AT30 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 initially included, or are installed after shipment.

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 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:

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.

i

PLEASE READ AND FOLLOW

ALL SAFETY INSTRUCTIONS

NOTICE

1. Before using the AT30, read all instructions and cautionary markings on:

A) this equipment, B) battery, and C) any other equipment to be used in conjunction with the AT30.

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 AT30 is off, to prevent arcing or burning.

6. Do not operate the AT30 if it has been damaged in any way. Refer to qualified service personnel.

7. Do not disassemble the AT30. Only qualified service personnel should attempt repairs. Incorrect reassembly may result in explosion, electrical shock, or fire.

8. Do not install the AT30 outdoors, or in wet or damp locations, unless specifically ordered for that environment.

9. Do not use the AT30 for ANY purpose not described in this manual.

! WARNING

1. Do not touch any uninsulated parts of the AT30, especially the input and output connections, as there is the possibility of electrical shock.

2. During normal operation, batteries may produce explosive gas. Never smoke, use an open flame, or create arcs in the vicinity of the AT30 or the battery.

3. Turn the AT30 off before connecting or disconnecting the battery to avoid shock hazards and/or equipment damage.

4. De-energize and lock out all ac and dc power sources to the AT30 before servicing.

5. Do not operate the AT30 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.

6. Do not operate the AT30 with the acrylic safety shield or any other supplied guards removed or improperly installed.

ii

HOW TO READ THE AT30 MODEL NUMBER ......................................... Inside Front Cover MANUFACTURER'S WARRANTY.............................................................. Removable Form IMPORTANT SAFETY INSTRUCTIONS................................................................................i

1 Receiving and Installing the AT30 Battery Charger

1.1 Storing the AT30

1.2 Reporting shipping damage

1.3 Unpacking and inspecting the AT30

Inspection checklist

1.4 Moving the AT30

Enclosure type and weight table

1.5 Mounting the AT30

1.5.1 Floor-Mounting the AT30

1.5.2 Wall-Mounting the AT30

1.5.3 Rack-Mounting the AT30

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

1.10 Wiring to the remote alarm contacts

Auxiliary Alarm Relay PC Board (optional)

1.11 Installing the temperature compensation probe (optional) Using temperature compensation

1.12 Installing the AT30 for remote communications (optional)

1.13 Installing the AT30 for forced load sharing (optional)

2 Operating the AT30 Battery Charger

2.1 Starting the AT30

2.1.1 Understanding the start-up sequence

2.1.2 Checking the installation

2.1.3 Starting the AT30

Using the digital meter Factory settings table

2.2 Using the AT30 front panel features

2.2.1 If the meter displays an error message

2.2.2 Selecting the meter mode

2.2.3 Selecting the Float or Equalize mode

2.2.4 Choosing the Equalize method

Manual Timer method Manual Equalize method Auto-Equalize Timer method

2.2.5 Testing the front panel indicators

2.2.6 Testing the Auxiliary Alarm Relay PC Board (optional)

2.2.7 Interpreting the alarm indicators

iii

2.3 Setting the AT30 parameters

2.3.1 Understanding parameter settings

2.3.2 Setting the Float and Equalize voltages

2.3.3 Setting the Equalize timer

2.3.4 Setting the Alarms

Setting the high and low dc voltage alarms Adjusting ground detection sensitivity Disabling the ground detection alarm

2.3.5 Setting the Current Limit value

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

Sample preventive maintenance procedure

3 Servicing the AT30 Battery Charger

3.1 A step-by-step troubleshooting procedure

3.2 Interpreting front panel error messages

3.3 Using the troubleshooting chart

3.4 Troubleshooting chart begins on

3.5 Replacing defective components

3.6 Ordering replacement parts

APPENDIX A: AT30 Performance Specifications APPENDIX B: Field Installable Accessories APPENDIX C: Standard Drawings *

Outline: AT30 Batt Chgr NEMA-1 Style-5018 / -5030 / -163 Enclosure..........................66 / 68 / 70 Internal Component Layout: AT30 Style-5018 / -5030 / -163 Encl w/Common Opts.....72 / 74 / 76 Instrument Panel / PC Board Detail: AT30 Series Battery Charger Schematic: AT30 Series Battery Charger - Standard w/o Options Schematic: AT30 Series Battery Charger - with Common Options Connection Diagram: AT30 Battery Charger - Power Wiring w/Common Options Connection Diagram: AT30 Battery Charger - Control (Signal) Wiring Connection Detail: AT30 Battery Charger - I/O Panels & Rectifier Assemblies

APPENDIX D: Recommended Float/Equalize Voltages / Temp. Compensation APPENDIX E: DNP3 Level 2 / Modbus Communications Module APPENDIX F: Forced Load Sharing APPENDIX G: CE Grounding Compliance APPENDIX H: Remote Shutdown APPENDIX J: Battery Open Alarm

MANUAL SPECIFICATIONS

RELATED DOCUMENTS (web-based content).......................................... Inside Back Cover

* A customized record drawing package is available for your particular 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 AT30 manufacturer.

RECEIVING THE AT30

1. RECEIVING THE AT30

1.1. STORING THE AT30

If you store the AT30 for more than a few days before installation, store it the 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 AT30 (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 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

� 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 and Quick Setup Sheet are supplied.

� You received all items on the packing list.

INSTALLING THE AT30

1.4. MOVING THE AT30

Once you have established that the AT30 is undamaged, identify the enclosure style of your unit. 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

Comprehensive weight data for the different models is available in the AT30 product literature (JF5018-00). The four standard NEMA Type 1 enclosures do not feature top lifting eyes for moving. Move the AT30 with a forklift whenever possible, using the supplied shipping pallet.

Place the AT30 onto a floor-mount installation using a forklift, lifting the enclosure from the bottom between the mounting legs. To lift the Style- 5018 enclosure into a wall-mount or rack-mount installation, use a heavy-duty sling or a scissor lift.

For further AT30 standard cabinet information, refer to the table below and the standard drawings featured in Appendix C, starting on page 66.

NEMA-1 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 http://www.atseries.net/PDFs/JF5018-00.pdf http://www.atseries.net/PDFs/JE5085-00.pdf http://www.atseries.net/PDFs/JE5088-99.pdf http://www.atseries.net/PDFs/JE5086-00.pdf http://www.atseries.net/PDFs/JE5089-99.pdf http://www.atseries.net/PDFs/JE5095-00.pdf http://www.atseries.net/PDFs/JE5098-99.pdf http://www.atseries.net/PDFs/JE5096-00.pdf http://www.atseries.net/PDFs/JE5099-99.pdf

1.5. MOUNTING THE AT30

The AT30 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 AT30 enclosure from the table below.

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

Floor-mounting is the standard means of installing all the AT30 enclosures. When floor-mounting the AT30, consider the following:

1. Refer to the outline drawings in Appendix C, starting on page 66, for the overall footprint of the Style-5018, Style-5030, and Style-163 enclosures.

2. Be conscious of planned ac input and dc output wiring to the AT30, selecting conduit entrances carefully. Note the standard pre-fab conduit knockouts located on the sides (and sometimes tops) of the enclosures.

3. The location:

• Should be free of drips and splatter. If falling particles and liquids are a problem, install NEMA-2 type drip shield accessory (EI0191-0#). For kit availability, see ordering information in Appendix B on page 65.

• 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. Allow at least 36in / 914mm front clearance for access to the AT30 for operation and maintenance.

PROCEDURE (Style-5018)

1. Install four (4) 0.25in / 6.4mm anchor bolts into the floor, per the mounting dimensions featured in the outline drawing (JE5085-00).

2. Carefully lift the AT30 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.

3. Add appropriate mounting hardware onto the floor-mounting anchor bolts and tighten securely.

PROCEDURE (Style-5030)

1. Install four (4) 0.375 / 9.5mm or 0.5in/12.7mm anchor bolts into the floor, per the mounting dimensions featured in the outline drawing (JE5086-00).

PROCEDURE (Style-163 / Style-198)

1. Install four (4) 0.5in/12.7mm anchor bolts into the floor, per the mounting dimensions featured in the outline drawings (JE5095-00 / JE5096-00).

GRAPHICS - STANDARD NEMA-1 TYPE AT30 ENCLOSURES

Style-5018 see outline drawing

JE5085-00

Style-5030

JE5086-00

Style-163

JE5095-00

http://www.atseries.net/PDFs/JE5086-00.pdf http://www.atseries.net/PDFs/JE5095-00.pdf http://www.atseries.net/PDFs/JE5096-00.pdf http://www.atseries.net/PDFs/JE5085-00.pdf http://www.atseries.net/PDFs/JE5086-00.pdf http://www.atseries.net/PDFs/JE5095-00.pdf

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

To install the AT30 onto a vertical surface, the standard Style-5018 enclosure does not need to be modified, but a special wall-mounting accessory (EI5008-00) is required. For kit availability see ordering information in Appendix B on page 65. The kit includes two (2) mounting brackets, appropriate hardware, and Installation Instructions (JA5063-00) for the wall-mounting procedure.

When wall-mounting the AT30, consider the following:

1. The wall must be strong enough to properly support the weight of the AT30 and the mounting brackets. Comprehensive weight data for the different models is available in the AT30 product literature (JF5018-00). The weight of your AT30 may be different from the literature value, depending on supplied features, options, or accessories.

knockouts located on the sides the Style-5018 enclosure.

problem, install NEMA-2 type drip shield accessory (EI0191-0#). For

PROCEDURE

1. Install eight (8) 0.25in / 6.4mm anchor bolts (not supplied) rated to support the AT30 weight plus a safety factor of at least two (2) times, into the wall.

2. Mount the triangular brackets to the wall.

3. Carefully lift the Style-5018 enclosure onto the mounted triangular brackets.

4. Use the supplied 0.25in / 6.4mm hardware to mount the enclosure to the wall-mounting brackets and tighten securely.

5. Refer to the graphics on the opposite page for the AT30 Style-5018 wall-mounting pattern and enclosure footprint.

6. Dimensions are in/mm.

http://www.atseries.net/PDFs/JA5063-00.pdf

GRAPHICS - WALL-MOUNTING THE AT30

1. Refer to the Style-5018 enclosure outline drawing (JE5085-00) in

Appendix C on page 66 for overall size, mounting dimensions, and cabinet specifications.

2. See Installation Instructions (JA5063-00) for the special Style-5018 wall-mounting procedure.

http://www.atseries.net/PDFs/JA5063-00.pdf

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

Smaller AT30s can be installed in 23-24in /584-610mm relay racks with standard EIA hole spacing. The Style-5018 enclosure does 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

65. The kit includes two (2) mounting brackets, hardware, and Installation Instructions (JA0091-03) for the rack-mounting procedure.

When rack-mounting the AT30, consider the following:

1. The relay rack must be strong enough to properly support the weight of the

AT30. Comprehensive weight data for the different models is available in the AT30 product literature (JF5018-00). The weight of your AT30 may be different from the literature value, depending on supplied features, options, or accessories.

knockouts located on the sides of the enclosures. Ensure that planned conduit is accessible after the AT30 is rack-mounted.

problem, install a NEMA-2 type drip shield accessory (EI0191-02). For

1. Attach the two (2) relay rack-mounting brackets to the sides of the Style-5018 enclosure, using the four (4) small pre-fab knockouts as guides.

2. Mount the brackets to the AT30, using the supplied 0.25in / 6.4mm hardware and tighten securely.

3. Using a scissor lift, guide the AT30 into the front face of the 23in / 584mm EIA relay rack.

4. Adjust the height of the AT30 and mount in place using appropiate hardware (not supplied).

5. Refer to the graphics on the opposite page for the rack-mounted enclosure footprint.

http://www.atseries.net/PDFs/JA0091-03.pdf

GRAPHICS - RACK-MOUNTING THE AT30

1. Rack-mount AT30 Style-5018 enclosures are installed from the front.

2. Refer to the Style-5018 enclosure outline drawing (JE5085-00) in

Appendix C on page 66 for overall size and cabinet specifications.

3. Refer to the detailed Installation Instructions (JA0091-03) supplied with the kit for the special rack-mounting procedure.

http://www.atseries.net/PDFs/JA0091-03.pdf

1.6. CHANGING THE TRANSFORMER TAPS

...! CAUTION... Before connecting external power to the AT30, verify the ac input voltage listed on the data nameplate decal, and the tag attached to the ac breaker (CB1). The power isolation transformer (T1) is designed with an ac input voltage tolerance of +10% to -12%.

If available on-site ac supply voltage does not match the AT30 input requirements, you may need to replace certain ac components. See Section 3.6 on page 62 for ordering replacement parts. Failure to use properly rated components may damage the AT30.

If your AT30 was supplied with one of the following ac input voltage features, the transformer (T1) is re-tappable:

• 208 or 240 Vac 60Hz

• 220 or 240 Vac 50/60Hz

• 380 or 416 Vac 50/60Hz

• 550 or 600 Vac 60Hz

If the AT30 was supplied with the 480 Vac 60Hz ac input feature, the transformer will only accept the listed voltage. Do not attempt to re-tap this transformer. If the transformer is not re-tappable, a full ac feature change is needed.