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ESCR INSTRUCTION MANUAL ESCR Instruction Manual ECN/DATE CPN 117485 18969 – 01/11 18935 – 12/10 18363 – 07/09 18288-05/09 106 BRADROCK DRIVE DES PLAINES, IL. 60018-1967 (847) 299-1188 FAX: (847)299-3061 ISSUE DATE: 18014-9/08 INSTRUCTION DRAWING NUMBER: LESCR-1 P25- Page 1 of 18 ESCR INSTRUCTION MANUAL IMPORTANT SAFETY INSTRUCTIONS FOR THE LA MARCHE POWER CONVERSION EQUIPMENT SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions for the La Marche Power Conversion Equipment. Before using this equipment, read all instructions and cautionary markings on (1) unit, (2) battery, and (3) product using the battery. CAUTION: To reduce risk of injury and/or damage to the batteries, use only the type of batteries specified on the charger. Do not expose equipment to rain or snow. Do not operate equipment if it has received a sharp blow, been dropped, or otherwise damaged in any way; take it to a qualified serviceman. Do not disassemble this unit; take it to a qualified serviceman when service or repair is required. Incorrect re-assembly may result in a risk of electric shock or fire. To reduce risk of electric shock, disconnect this unit from the a.c. supply, and batteries and loads before attempting any maintenance or cleaning. Turning off controls will not reduce this risk. WARNING – THERE IS A RISK OF EXPLOSIVE GASSES AND WORKING IN THE VICINITY OF A BATTERY IS DANGEROUS. SOME BATTERIES GENERATE EXPLOSIVE GASES DURING NORMAL BATTERY OPERATION. FOR THIS REASON, IT IS OF UTMOST IMPORTANCE THAT EACH TIME BEFORE USING THIS UNIT, YOU READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS EXACTLY. To reduce risk of battery explosion, follow these instructions and those published by the battery manufacturer and manufacturer of any equipment you intend to use in the vicinity of the battery. Review cautionary marking on all products. PERSONAL PRECAUTIONS: 1. Someone should be within range of your voice or close enough to come to your aid when you work near a battery. 2. Have plenty of fresh water and soap nearby in case the battery electrolyte contacts skin, clothing, or eyes. 3. Wear complete eye protection and clothing protection. Avoid touching eyes while working near a battery. 4. If the battery electrolyte contacts skin or clothing, wash immediately with soap and water. If the electrolyte enters the eye, immediately flood the eye with running cold water for at least ten (10) minutes and get medical attention immediately. 5. Never smoke or allow a spark or flame in vicinity of a battery. 6. Be extra cautious, DO NOT drop metal onto a battery. It might spark or short-circuit the battery or cause an explosion. 7. Remove personal metal items such as rings, bracelets, necklaces, and watches when working with a battery. A battery can produce a short-circuit current high enough to weld these items causing severe burns. 8. NEVER charge a frozen battery. Page 2 of 18 ESCR INSTRUCTION MANUAL PREPARING TO CHARGE 1. If it is necessary to remove the battery connections, always remove grounded terminal from the battery first. Make sure all loads are disconnected and unit is off, so as not to cause an arc. 2. Be sure the area around the battery is well ventilated while the battery is being charged. 3. When cleaning battery terminals, be careful to keep corrosion from coming in contact with eyes. 4. Study all the battery manufacturer’s specific precautions such as removing or not removing cell caps while charging, recommended rates of charge, and maintenance procedures. UNIT LOCATION • Never place this unit directly above the standard flooded battery. Gases from the battery will corrode and damage equipment. A sealed maintenance free or valve regulated lead acid (VRLA) may be placed below this equipment. • Never allow the battery electrolyte to drip on this unit when reading the specific gravity or filling the battery. • Do not operate this unit in a closed-in area or restrict ventilation in any way. • Do not set any battery on top of this unit. D.C. CONNECTION PRECAUTIONS Connect and disconnect d.c. output cables only after setting all of this unit's switches to off position and removing a.c. input supply. GROUNDING INSTRUCTIONS This battery charger should be connected to a grounded, metal, permanent wiring system; or an equipment grounding conductor should be run with circuit conductors and connected to equipmentgrounding terminal or lead on battery charger. Connections to battery should comply with all local codes and ordinances. CAUTION: DO NOT PULL ON OUTPUT CABLES WHEN DISCONNECTING CHARGER FROM BATTERY. Page 3 of 18 ESCR INSTRUCTION MANUAL RECEIVING INSTRUCTIONS AND GENERAL EQUIPMENT INFORMATION CAUTION: To ensure safe installation and operation, the information given in the instruction manual should be read and understood before installing or using the equipment. RECEIVING INSTRUCTIONS Unpacking and Inspection: Examine the shipping crate upon arrival. If there is obvious damage, describe on the receiving documents. Within a few days after delivery, the equipment should be uncrated and carefully inspected for hidden damages. When removing packaging material, be careful not to discard any equipment, parts, or manuals. If any damage is detected you should: 1. File a claim with the carrier within five (5) days. 2. Send a copy of the claim to La Marche Mfg. Co. 3. Call La Marche Mfg. For a RETURN MATERIAL AUTHORIZATION NUMBER. Failure to properly file a claim for shipping damages, or provide a copy of the claim to La Marche Mfg., may void warranty service for any physical damages reported for repair. HANDLING WARNING: Equipment can be very heavy, and top-heavy. Use adequate manpower or equipment for handling. Until the equipment is securely mounted, care must be used to prevent the equipment from being accidentally tipped over. NOMENCLATURE PLATES Each piece of La Marche Mfg. Equipment shipped is identified by part number on the nomenclature plate. ADJUSTMENTS All equipment is shipped from the factory fully checked and adjusted. Do not make any adjustments unless the equipment has been powered-up and the settings have been determined to be incorrect. SPARE PARTS To minimize downtime during installation or normal service, it is advisable to purchase spare fuses, circuit boards and other recommended components. Please refer to the list of recommended spare parts and their La Marche Mfg. Part numbers included with the instruction manual. It is recommended that spare fuses be ordered for all systems. To order spare parts, please contact La Marche Mfg. (847)-299-1188 during business hours and ask for the Parts Department. Page 4 of 18 ESCR INSTRUCTION MANUAL INSTALLATION AND OPERATING INSTRUCTIONS - ESCR The LaMarche model ESCR is a microprocessor controlled SCR rectifier designed to charge engine start batteries. It features adjustable Float and Equalize voltages, automatic sensing AC Input, soft start, equalize timer and is configurable for Flooded Lead Acid, NiCad or VRLA batteries. Prior to hooking up the battery, the charger needs to be configured for the battery to be charged. This is done in the configuration mode. Enter the basic configuration mode by pressing the CONFIGURE/OK button, selecting BASIC and then setting the proper parameters. Once properly installed and adjusted, the rectifier will maintain the battery in a fully charged condition. Install the rectifier so that the flow of air through the ventilators is not obstructed. Terminals to hook up AC and DC connections are provided on a terminal strip within the unit. When hooking up the DC cables to the battery, be certain the positive terminal of the charger is connected to the positive battery terminal and the negative terminal is connected to the negative battery terminal. Page 5 of 18 ESCR INSTRUCTION MANUAL After the rectifier has been installed, follow the battery manufacturers specifications for equalize, give the battery a freshening charge to make certain it is fully charged by putting the rectifier in the Equalize mode. To give an equalizing charge, it is only necessary to press the Float/Equalize button. The rectifier will automatically hold the cell voltage at the equalizing voltage and will drop back to float voltage when the Float/Equalize button is pressed again. Alternatively, a timed equalize cycle can be selected. In this case the rectifier will drop back to float when the specified number of hours has passed. In normal operation, the ESCR Float Charger maintains a constant battery voltage from no load to full load with a variation of no more than +0.5% over the specified input voltage, frequency and ambient temperature ranges. If the battery is discharged, the charger will recharge the battery from its current limiting capacity to full charge. The inherent design of the rectifier provides compensation for line voltage variations of +/-10%. The DC output current is limited to provide for complete protection. The current limiting feature allows for the unit to carry overloads and limits the output to a maximum of 105% of the rated output. CONFIGURATIONS The ESCR rectifier is available in the following configurations: ESCR-20/10-12/24V-AV1 This model can be configured for 12V-10AMP or12V-20AMP or 24V-10AMP ESCR-40/20-12/24V-AV1 This model can be configured for 12V/40AMP or 24V-20AMP DC output configuration is field selectable and must be configured by user. AC input is 120V/208V/240VAC and is selected automatically when power is applied. OUTPUT RATINGS DC VOLTAGE: FLOAT VOLTAGE EQUALIZE VOLTAGE 2.17 volts/cell (LEAD) 2.25 volts cell (VRLA) 1.40 volts/cell (NiCad) 2.33 volts/cell (LEAD) 2.27 volts/cell (VRLA) 1.55 volts/cell (NiCad) VOLTAGE RANGE: FLOAT EQUALIZE 2.12-2.3 volts/cell + 0.1 volt (LEAD) (VRLA) 1.39-1.45 volts/cell + 0.1 volts (NICAD) 2.25-2.4 volts/cell +0.1volt (LEAD) (VRLA) 1.5-1.60 volts/cell + 0.1volts (NICAD) OUTPUT CURRENT: ESCR-20/10-12/24V-AV1: 20A@12V setting; 10A@24V setting; ESCR-40/20-12/24V-AV1: 40A@12V setting; 20A@24V setting; Page 6 of 18 ESCR INSTRUCTION MANUAL REGULATION: Steady state output voltage remains within + 0.5% of rated voltage for any load current from no load to full load and for input voltages within the specified ranges. FILTERING: Less than 1V RMS at full load MEAN TIME BETWEEN FAILURES: The mean time between failures (MTBF) is 150,000 hours. INPUT RATINGS INPUT VOLTAGE: 120V/208-240VAC + 10%, 50/60HZ The correct voltage is automatically selected when power is applied. INPUT CURRENT: Model Number AC Input Amps ESCR-20/10-12/24V-AV1 ESCR-40/20-12/24V-AV1 4.0/1.6-2.0 6.0/2.6-3.0 6.0/2.6-3.0 10/5.0-5.0 10/5.0-5.0 Volts 120/208-240 120/208-240 120/208-240 120/208-240 120/208-240 STANDARD FEATURES INPUT PROTECTION Dual AC fusing with Surge Protection OUTPUT PROTECTION Fuse with Surge Protection Reverse Polarity Protection Page 7 of 18 DC Output Amps Volts 10 20 10 12 12 24 40 20 12 24 ESCR INSTRUCTION MANUAL CONTROLS FLOAT / EQUALIZE BUTTON Allows user to select Float mode or Equalize mode. LAMP TEST Allows user to perform a lamp test without affecting the operation of the rectifier RESET /BACK BUTTON In normal operation pressing this button will restart the rectifier. In the CONFIGURE mode it allows the user to navigate back to a previous screen. CONFIGURE/OK BUTTON Pressing this button places the rectifier in the configure mode, allowing the user to set charger parameters in Basic Settings as well as Float Voltage, Equalize Voltage, Equalize Timer Current Limit, Temperature Compensation and Alarm settings. INDICATORS/ALARMS DIGITAL VOLT / AMP METER Displays the output voltage and amperage FLOAT LED (Green) This lamp will illuminate when the rectifier is in the Float mode EQUALIZE LED (Amber) This lamp will illuminate when the rectifier is in the Equalize mode AC ON (Green) This lamp will illuminate when AC voltage is present at the input terminals CHRGR FAIL LED (Red) The Charger Fail LED will illuminate when a low voltage and low current condition are present simultaneously. A set of form “C” contacts is provided also. BATT. FAULT LED (Red) The Battery Failure LED illuminates to indicate a battery problem. Conditions that will cause this LED to illuminate are an open or high resistance battery, or a missing battery. CURRENT LIMIT (Red) This lamp will illuminate when the rectifier is operating in a current limit condition HIGH DC (Red) This lamp illuminates when the DC output voltage of the rectifier exceeds the preset high voltage alarm value. A set of form “C” contacts is also provided. LOW DC LED (Red) This lamp will illuminate when the DC output voltage drops below a preset low voltage alarm value. A set of form “C” contacts is also provided. AC FAIL (contacts only) A set of form “C” contacts is provided for an AC Power Failure Alarm annunciation. Page 8 of 18 ESCR INSTRUCTION MANUAL ENVIRONMENTAL RATINGS OPERATING AMBIENT TEMPERATURE -20° to 50° C derated up to 70° C STORAGE TEMPERATURE -40° TO 85° C RELATIVE HUMIDITY 5% to 95% noncondensing INSTALLATION INFORMATION MINIMUM WIRE SIZES Table 2 lists the AC input and the DC output minimum wire size requirements. At distances exceeding 10 feet, the DC wire size should be chosen to keep the voltage difference between the units DC output terminals and the battery at less than ½ volt when the unit is fully loaded. See Section 7.6 for “POWER CABLING FORMULAS”. The total loop length is twice the distance from the wiring point to the unit. NATIONAL CODES These wire sizes are based on those recommended in the National Electric Code Table 310-16 for copper wire at 75 degrees C conductor temperature operating in an ambient of 30 degrees C. For higher operating temperatures refer to the derating factors in the National Electric Code Table 310-16. GROUND TERMINAL This terminal should be connected to an earth ground. The size of the conductor is based on National Electric Code Table 250-95 for copper wire at 75 degrees C. (See Table #2 for recommended wire sizes.) MOUNTING Install the rectifier so that the flow of air through the ventilators is not obstructed. Page 9 of 18 ESCR INSTRUCTION MANUAL WIRE SIZE TABLE POWER CABLING FORMULAS The following section may be used to calculate the wire size requirements for wire lengths in excess of 10 ft. (Refer to TABLE 3) CMA= CROSS SECTION OF WIRE IN CIRCULAR MILS. A = CURRENT DRAIN IN AMPERES. LF = CONDUCTOR LOOP FEET. MAX AMP= MAXIMUM ALLOWABLE CURRENT FOR A GIVEN VOLTAGE DROP (IN AMPERES). AVD = ALLOWABLE VOLTAGE DROP. K = 11.1 CONSTANT FACTOR FOR COMMERCIAL (TW TYPE) COPPER WIRE (KS5482-01) WIRE SIZE REQUIRED CMA = (A*LF*K) /AVD CURRENT CAPACITY IN AMPS- SEE TABLE 3 MAX AMPS = (CMA*AVD)/(LF*K) Page 10 of 18 ESCR INSTRUCTION MANUAL CONFIGURING THE RECTIFIER CAUTION: WHEN THE RECTIFIER IS IN THE CONFIGURATION MODE AND BATTERY IS DISCONNECTED THE OUTPUT VOLTAGE WILL DROP TO 0 VOLTS! WITH BATTERY CONNECTED, CURRENT WILL DROP TO 0 AMPERES ! Enter the configuration mode by pressing CONFIGURE/OK button. Use the UP and DOWN arrows on the side of the LCD display to navigate the menu selections. Use the CONFIGURE/OK button to make a selection. Use the BACK button to go back to a previous screen. The following features are available to be configured: BASIC: Allows • • • • • • • • selection of the output configuration (voltage/current) and the number of cells. Enter configuration mode by pressing CONFIGURE/OK button. Select BASIC Select O/P VOL. & CURR. (Output Voltage and Current) Select the rectifier configuration needed. Return to previous menu by pressing BACK button Select NO.S OF CELLS Select the number and type of battery cells to be charged Return to configuration menu by pressing the Reset/Back button FLOAT VOLTAGE: Allows the selection of per cell voltage for float operation. • Select FLOAT VOLTAGE from configuration menu • Set to the voltage recommended by battery manufacturer EQUALIZE VOLTAGE: Allows the selection of per cell voltage for Equalize operation. • Select EQUALIZE VOLTAGE from configuration menu • Set to the voltage recommended by battery manufacturer EQUALIZE TIMER: Allows • • • selection of Equalize hours and Equalize cycles (manual/automatic). Select EQUALIZE TIMER from configuration menu Select EQUALIZE HOURS Select and set the hours that the rectifier will be in the EQUALIZE mode. Timer can be set from 1hr to 144hrs. • Select EQUALIZE MODE and set for MANUAL or one of the automatic modes: MANUAL: 7 DAYS: 14 DAYS: 30 DAYS: AUTO–AC FAIL: AUTO–DC LOW: Equalize cycle is started manually Equalize cycle is started automatically every 7 days Equalize cycle is started automatically every 14 days Equalize cycle starts automatically every 30 days Equalize cycle starts automatically when AC input power is restored after a power failure (AC power has to be off for 5 minutes for this mode to be activated) Equalize cycle starts automatically if battery voltage falls below the Low Voltage Alarm set point In any mode, rectifier will return to Float mode at the end of the equalize cycle. Page 11 of 18 ESCR INSTRUCTION MANUAL CURRENT LIMIT: Allows adjustment of the current limit from 50% to 105% of rated output. • Select LIMIT CURRENT from configuration menu • Select current limit as a percentage of the rated output current of the rectifier. Current limit can be adjusted from 50% to 105% TEMPERATURE COMPENSATION: Allows • • • enable or disable of the temperature compensation feature. Select COMPENSATE. TEMP. from configuration menu Select COMP.TEMP Select DISABLE or ENABLE ALARM SETTINGS: Allows • • • setting the alarm thresholds for the provided alarms and the time delays for it. Select ALARM SETTING from the configuration menu. In the ALARM SETTING menu select ALARM DELAY Select the alarm delay in seconds. Delay can be set from 1 second to 30 seconds. • • In the ALARM SETTING menu select DC LOW VOLTAGE Select the desired low voltage alarm point in vpc (volts per cell). • • In the ALARM SETTING menu select DC HIGH VOLTAGE Select the desired high voltage alarm point in vpc (volts per cell) • • In the ALARM SETTING menu select DC LOW CURRENT Select the desired low current alarm point • • In the ALARM SETTING menu select AC FAIL VOLTAGE Select the AC voltage operating range for the rectifier. Alarm will activate when the AC voltage is above or below the selected range. • To reset the rectifier settings to the original factory settings, scroll to FACTORY SETTING in the configuration menu. Select FACTORY SETTING. Page 12 of 18 ESCR INSTRUCTION MANUAL Page 13 of 18 ESCR INSTRUCTION MANUAL Page 14 of 18 ESCR INSTRUCTION MANUAL Page 15 of 18 ESCR INSTRUCTION MANUAL General Maintenance Procedure Yearly 1. 2. 3. 4. Blow out rectifier with a low-pressure air hose. Make sure all connections are tight. Perform a visual check on all internal components. Check front panel meters and alarms for accuracy. 3rd Year REPEAT ABOVE WITH THE ADDITION OF: 1. Check capacitors for leakage. 5th Year REPEAT ALL, WITH THE ADDITION OF: 1. Filter capacitors should be replaced. 10th Year REPEAT ALL WITH THE ADDITION OF: (except replacing capacitors, they should be replaced every 5years) 1. Check magnetics, components and wiring for signs of excessive heat. Page 16 of 18 ESCR INSTRUCTION MANUAL MANUFACTURER’S WARRANTY All La Marche Manufacturing Co. equipment has been thoroughly tested and found to be in proper operating condition upon shipment from the factory and is warranted to be free from any defect in workmanship and material that may develop within three (3) years from date of purchase. Any part or parts of the equipment (except fuses, d.c. connectors and other wear-related items) that prove defective within a three (3) year period shall be replaced without charge providing such defect, in our opinion, is due to faulty material or workmanship and not caused by tampering, abuse, misapplication or improper installation. Should a piece of equipment require repair during the warranty period, the equipment can be returned to the La Marche factory to have the inspection, parts replacements and testing performed by factory personnel. Should it be necessary to return a piece of equipment or parts to the factory, the customer or sales representative must obtain authorization from the factory. If upon inspection at the factory, the defect was due to faulty material or workmanship, all repairs will be made at no cost to the customer during the first three years. Transportation charges or duties shall be borne by purchaser. In accepting delivery of the equipment, the purchaser assumes full responsibility for proper installation, installation adjustments and service arrangements. Should minor adjustments be required, the local La Marche sales representative should be contacted to provide this service only. All sales are final. Only standard LaMarche units will be considered for return. A 25% restocking fee is charged when return is factory authorized. Special units are not returnable. In no event shall La Marche Manufacturing Co. have any liability for consequential damages, or loss, damage or expense directly or indirectly arising from the use of the products, or any inability to use them either separately or in combination with other equipment or materials, or from any other cause. In addition, any alterations of equipment made by anyone other than La Marche Manufacturing Co. renders this warranty null and void. La Marche Manufacturing Co. reserves the right to make revisions in current production of equipment, and assumes no obligation to incorporate these revisions in earlier models. The failure of La Marche Manufacturing Co. to object to provisions contained in customers' purchase orders or other communications shall not be deemed a waiver of the terms or conditions hereof, nor acceptance of such provisions. The above warranty is exclusive, supersedes and is in lieu of all other warranties, expressed or implied, including any implied warranty of merchantability or fitness. No person, agent or dealer is authorized to give any warranties on behalf of the Manufacturer, nor to assume for the Manufacturer any other liability in connection with any of its products unless made in writing and signed by an official of the manufacturer. Page 17 of 18 ESCR INSTRUCTION MANUAL La Marche Mfg. Co. Recommended Spare Parts for 116770 Rev A00 Spare Level A ESCR-20/10-12/24V/AV1 Part.Number........................ Description.............. Qty...... UM 118798 P24CCA-S2A-348-0101 DISPLAY CARD 1 EA 118738 P24H-S8-26-6 RIBBON CABLE ASSEMBLY 1 EA 118757 P24-P2A-40-47KM3 ELECTROLYTIC CAPACITOR C1 1 EA 118768 P24F-P8-G1-B20 DC FUSE (ATO 20A 32V) F3 2 EA 118945 P24FU-P8-D1-B7 AC FUSE 7A 250V F1, F2 2 EA Recommended Spare Parts for 117300 Rev A00 Spare Level A ESCR-40/20-12/24V/AV1 Part.Number........................ Description.............. Qty...... UM 118798 P24CCA-S2A-348-0101 DISPLAY CARD 1 EA 118738 P24H-S8-26-6 RIBBON CABLE ASSEMBLY 1 EA 118757 P24-P2A-40-47KM3 ELECTROLYTIC CAPACITOR C1, C2 2 EA 118779 P24F-P8-G1-B30 DC FUSE (ATO 30A 32V) F3 2 EA 21259 P8-D1-B15 AC FUSE 15A 250V F1, F2 2 EA Page 18 of 18