La Marche Manufacturing Company www.lamarchemfg.com Option 46 Series Digital Combined Accessory Package Installation and Operation Manual This manual is subject to change without notice. You may obtain the newest version of the manual at www.lamarchemfg.com 106 Bradrock Dr. Des Plaines, IL 60018-1967 CPN 110313 Instruction Drawing Number: P25-LOPT46SERIES-1 i Tel: 847-299-1188 Fax: 847-299-3061 Revision A04 Rev. Date: 03/17 ECN: 21360
1.0 Option 46 Series Operation 1.1 General Description The 46 series option includes the user-interface LCD display panel which has three LED indicators on the front panel and two LED indicators on the door. Two LEDs on the panel are used as status indicators for Float and Equalize mode and one LED refers to the alarm present (if any). Refer to Figure 1. Four buttons are provided on the display for menu navigation RESET, MODE, UP, and DOWN Figure 1 LCD Display Showing System Outputs (while in Float Mode) NOTE: In the 46J, 46Q, 46T, and 46U option, two LEDs will be provided on the front panel as positive ground and negative ground alarm indicators. Refer to Figure 2A. In the 46P and 46T option, an audible alarm with silence switch will be provided on the front panel. In the 46A option, ten LEDs will be provided on the front panel. The AC ON LED will illuminate (in green) whenever power is provided to the charger. The remaining nine LEDs will illuminate (in red) each under a specific alarm condition. Refer to Figure 2B. Figure 2A Negative and Positive Ground LEDs (On Front Panel 46J/Q/T/U Option) Figure 2B LED indicators (On Front Panel 46A Option) Pushing the UP or DOWN button changes the display. The following items can be displayed: EQ Timer Setting Displays what the Equalize timer is currently set to. Time until next Equalize Displays a countdown to the next Equalize charge cycle. Timer Mode Shows what Equalize timer mode the charger is currently in with a short description listed on the second line. When the charger is in Equalize mode, the display will change to show the DC output voltage and DC output current, as well as the time remaining in the current Equalize charge cycle. Pushing the UP or DOWN button will change the display in Equalize mode as well. Refer to Figure 3. Figure 3 LCD Display Showing System Output and EQ Timer (while in Equalize Mode) 2
1.2 Selecting the Charging Mode The digital display used in the 46 series has two modes for DC output voltage Float mode and Equalize mode. Float charging mode is used for all normal battery charging needs. Equalize mode is used when it is necessary to Equalize (or balance) the level of charge across all cells present in the battery. Two LEDs, marked Float and Equalize on the front panel, indicate the present mode of operation of the charger. If the charger is in Float mode, simply press the MODE button to switch into Equalize mode. If the charger is in Equalize mode, it will automatically switch back to Float mode after the designated Equalize time cycle is complete; alternatively, the charger can manually be switched to Float mode by pressing the MODE button. 2.0 Alarms The available alarms for the 46 Series are: Low Voltage1, Low Voltage2, End of Discharge, Low Current, Overload Current/Current Limit, High Voltage, High Voltage Shutdown, Positive Ground, Negative Ground, AC Power Failure, Charger Failure, Over Temperature, and Summary. The LCD display will show a message when an alarm is triggered, if applicable. Figures 4A 4E illustrate the alarm relays provided on the 198 relay board, dependent on the option. Each set of alarm relays have two sets of dry form C contacts which function identical to each other. Not all alarms have a set of alarm relays assigned and not all alarm relays function the same; refer to Table 1 for the logic of each relay. Figure 4A (46J/T Option) Figure 4B (46E/G/P Option) Figure 4C (46L Option) S2A-198 Relay Information Relay Function High DC Voltage Shutdown Low DC Current High DC Voltage Low DC Voltage 1/ Low DC Voltage 2 (End of Discharge) AC Power Failure Summary Positive Ground Negative Ground Logic Energize On Fail De-Energize On Fail Energize On Fail De-Energize On Fail De-Energize On Fail De-Energize On Fail Energize On Fail Energize On Fail Figure 4D (46Q Option) Figure 4E (46U Option) Table 1 NOTE: See schematic or manual cover page to determine which alarm option is included. 3
2.1 Alarm Contact Specifications Load Resistive Load (P.F. = 1) Contact Material Ag (Au clad) Maximum Allowed Current 2 A 0.5 A at 125 VAC Max. Operating Voltage and Current 0.25 A at 125 VDC 2 A at 30 VDC Max. Switching Capacity 62.50 VA 60 W Min. Permissible Load 10 ua, 10 mvdc 2.2 Alarm Definitions Table 2 AC POWER FAILURE ALARM will trigger, the green AC ON LED will turn off (if applicable), and the red AC FAILURE LED will turn on (if applicable) if the AC power to the charger is lost for longer than 5 seconds. The alarm will automatically reset when AC power is restored to the charger. When AC power is lost, the front panel display and indicators will remain powered by the connected batteries. LOW DC VOLTAGE ALARM will trigger and the red LOW DC VOLTAGE LED will turn on (if applicable) if the DC voltage falls below the specified voltage threshold of the alarm for longer than 5 seconds. The alarm will clear once the low DC voltage condition is no longer present. END OF DISCHARGE ALARM will trigger and the red BATTERY END OF DISCHARGE LED will turn on (if applicable) if the DC voltage falls below the specified voltage threshold of the alarm for longer than 5 seconds. The alarm will clear once the low DC voltage condition is no longer present. Some options will define this as an End of Discharge Alarm with a different threshold. HIGH DC VOLTAGE SHUTDOWN ALARM will trigger and the red HIGH DC VOLTAGE SHUT DOWN LED will turn on (if applicable) if the output DC voltage of the charger rises above the alarm threshold for longer than 20 seconds and there is load on the charger. If the High DC Voltage Shutdown alarm activates, the DC output of the charger shuts off to prevent irreversible damage to the battery. This alarm will stay latched until the charger is reset by isolating from all power sources or pushing the RESET button. NOTE: This alarm will not trigger if there is a Low Current alarm present. HIGH DC VOLTAGE ALARM will trigger and the red HIGH DC VOLTAGE LED will turn on (if applicable) if the output DC voltage rises above the specified voltage threshold of the alarm for longer than 5 seconds. The alarm will clear once the high DC voltage condition is no longer present. LOW DC CURRENT ALARM will trigger and the red LOW DC CURRENT LED will turn on (if applicable) if the output DC current of the charger falls below the alarm threshold for longer than 5 seconds. This alarm can be disabled if considered a nuisance alarm. OVERLOAD/CURRENT LIMIT LED will turn on (if applicable) if the DC current exceeds the specified current threshold of the alarm for longer than 5 seconds. SUMMARY ALARM will default trigger if any of the other alarms are triggered. There is no Summary alarm LED, only alarm contacts. The Low Current, AC Power Failure, Overload Current, and Ground Detection alarms can be removed from the Summary alarm, but are included by default. POSITIVE GROUND ALARM will trigger and the green POSITIVE GROUND LED will turn on if 1.2mA or greater current is measured between the positive terminal of the battery and earth ground for longer than 5 seconds. The alarm will clear once the positive ground fault is no longer present. NEGATIVE GROUND ALARM will trigger and the green NEGATIVE GROUND LED will turn on if 1.2mA or greater current is measured between the negative terminal of the battery and earth ground for longer than 5 seconds. The alarm will clear once the negative ground fault is no longer present. 4
NOTE: The Charger Failure alarm does not have an LED indicator on the front panel; if the alarm occurs, it will appear on the digital display. A Charger Failure alarm occurs when one of the following conditions are present: Simultaneous Low DC Voltage and Low DC Current, or High Voltage Shutdown. Alarm Delay (sec.) Summary Selectable Clearing Threshold Alarming Threshold (V/C) LED Indication (If Applicable) AC Power Failure 5 Yes - - AC FAILURE Low DC Voltage 5 No 5% 1.975 LA / 1.2 NC LOW DC VOLTAGE End of Discharge 5 No 5% (of shown DCV) 1.75 LA / 1.1 NC BATTERY END OF DISCHARGE High DC Voltage 5 No - 2.45 LA / 1.61 NC HIGH DC VOLTAGE High Voltage Shut Down 20 No - 2.5 LA / 1.65 NC HIGH DC VOLTAGE SHUTDOWN Low DC Current 5 Yes * * LOW DC CURRENT Overload/ Current Limit 5 Yes - Refer to Manual OVERLOAD / CURRENT LIMIT Summary 5 - - Other Alarms - Positive Ground 5 Yes - - POSITIVE GROUND Negative Ground 5 Yes - - NEGATIVE GROUND Charger Failure None - - Low DCV & Low DCA / High DCV Shutdown - Table 3 Alarm Default Values & Indications * Low Current alarming threshold is dependent on shunt size V/C Volts per Cell, LA Lead Acid, NC Nickel Cadmium NOTE: These recommended parameters are set as factory default settings. If required, change the alarm threshold levels after verifying with battery manufacturer. 2.3 Alarm Connection Procedure Before making any alarm connections, ensure that the AC power is off at the main breaker. Verify that no voltage is present by using a voltmeter at all AC and DC terminals. For relays mentioned as ENERGIZED on alarm condition: If it is desired that the annunciator be active until the alarm triggers, connect the annunciator leads to the NC and C contacts of the desired alarm (located on the relay alarm contacts on S2A-198 board). If it is desired that the annunciator be deactivated until the alarm triggers, connect the annunciator leads to the NO and C contacts of the desired alarm. For relays mentioned as DE-ENERGIZED on alarm condition: If it is desired that the annunciator be active until the alarm triggers, connect the annunciator leads to the NO and C contacts of the desired alarm (located on the relay alarm contacts on S2A-198 board). If it is desired that the annunciator be deactivated until the alarm triggers, connect the annunciator leads to the NC and C contacts of the desired alarm. 5
3.0 Adjusting Parameters All equipment is shipped from the factory fully checked and adjusted based on the customer order. Do not make any adjustments unless the equipment has been powered-up and the settings have been determined to be incorrect. If the settings have been determined to be incorrect, adjustments may be made as detailed below. 3.1 Customer Calibration Mode In Customer Calibration Mode, the customer can access and change various parameters. To access the Customer Calibration Mode, press both the UP and MODE buttons (press the UP button first - the LCD display should change. Hold it down and then press the MODE button) for about 5 seconds. After Customer Calibration Mode appears on the LCD display, release both buttons. Once in calibration mode, the customer can raise and lower values with the UP and DOWN buttons and can advance to the next parameter with the MODE button. After the last setting is passed, all settings will automatically be saved. If a setting is accidentally passed over, the customer must advance through the remaining features and restart calibration from the beginning. Alternatively, the customer can press the RESET button and restart calibration from the beginning. The calibration settings are listed in order below with a brief description and default values. NOTE: Some chargers may have additional settings included in the Customer Calibration menu; contact La Marche for further explanation of settings not mentioned below. The Customer Calibration menu is as follows: Low Voltage Alarm This setting changes the voltage threshold that causes the Low DC Voltage Alarm to activate. The default setting is 1.98 V/C (for Lead Acid batteries), based on the number of battery cells that the charger was designed for. The number and type of cells is listed on the charger s nameplate. (EX: A charger designed for 24L has a default Low Voltage alarm setting of 47.5VDC) Battery End of Discharge Alarm This setting changes the voltage threshold that causes the Battery End of Discharge Alarm to activate. The default setting is 1.75 V/C (for Lead Acid batteries), based on the number of battery cells that the charger was designed for. The number and type of cells is listed on the charger s nameplate. (EX: A charger designed for 24L has a default Battery End of Discharge alarm setting of 42VDC) High Voltage Shutdown Alarm This setting changes the voltage threshold that causes the High Voltage Shutdown Alarm to activate. The default setting is 2.50 V/C (for Lead Acid batteries), based on the number of battery cells that the charger was designed for. The number and type of cells is listed on the charger s nameplate. (EX: A charger designed for 24L has a default High Voltage Shutdown alarm setting of 60VDC) High Voltage Alarm This setting changes the voltage threshold that causes the High Voltage Alarm to activate. The default setting is 2.45 V/C (for Lead Acid batteries), based on the number of battery cells that the charger was designed for. The number and type of cells is listed on the charger s nameplate. (EX: A charger designed for 24L has a default High Voltage alarm setting of 58.8VDC) Low DC Current Alarm This setting changes the current threshold that causes the Low DC Current Alarm to activate. The default setting is dependent on the shunt size. This alarm can be disabled if considered a nuisance alarm by lowering the threshold value to OFF. Overload Current Alarm This setting changes the current value that causes the Overload Current Alarm to activate. EQ Timer Mode This setting changes the mode of the Equalize Timer. The Equalize timer mode determines when the charger will go into an Equalize charging cycle. The timer modes are Mode 0 (P0), Mode 1 (P1), Mode 2 (P2), Mode 3 (P3), and Mode 4 (P4). The default setting for the Equalize timer mode is Mode 0 (P0). The Equalize Timer Modes are discussed in further detail in Section 3.2. 6
EQ Timer Setting This setting changes the amount of time that the charger remains in the Equalize charging cycle once activated. When an Equalize cycle is started, the charger will remain in Equalize mode until the time selected by this setting has passed. By default, the Equalize timer is set for 8 hours. The battery manufacturer documentation should be referenced for battery specific settings. LCD Backlight This setting changes the behavior of the LCD Backlight. By default, the backlight is set to turn off two minutes after the last key press on the display membrane. Alternatively, the backlight can be set to Always ON. Modbus Address This setting changes the address of the Modbus. If the customer has purchased a Communication Board (Option 21P/21Q), this setting should be set to All in order to access further options of the communication board. Modbus Baud Rate This setting changes the Modbus Baud Rate. The default baud rate is 9600. The baud rate of the charger should be set to match the baud rate of the computer that is connected. Parity Type This setting changes the parity type. The default setting is None. 3.2 Equalize Timer Modes The 46 series offers five different modes of Equalize charging operation. The Equalize mode can be viewed on the charger display by using the UP or DOWN button to scroll through the menu. The Equalize mode can be changed via the Customer Calibration menu, refer to section 3.1. In all of the Equalize modes below, the charger will return to Float mode if the MODE button is pressed or when it completes its full charge time. Mode 0 (Displayed as P0 ) Mode 0 is a manual Equalize cycle and is the default setting for the charger. When the charger is set for Mode 0, the Equalize cycle must be activated manually. Once activated, the Equalize timer will turn on and the Equalize "LED" will light. The length of the timer is eight hours by default and can be changed via Customer Calibration. After the timer cycles to zero, the charger will immediately return to Float mode. Equalize mode will not start again until it is manually activated by the user. Mode 1 (Displayed as P1 ) Mode 1 is an automatic Equalize cycle that activates every 7 days. The length of the Equalize cycle is determined by the timer setting. The length of the timer is eight hours by default and can be changed via Customer Calibration. When the Equalize timer expires, the charger will immediately return to Float mode. Equalize mode will restart again after 7 days. Mode 2 (Displayed as P2 ) Mode 2 is an automatic Equalize cycle that activates every 14 days. The length of the Equalize cycle is determined by the timer setting. The length of the timer is eight hours by default and can be changed via Customer Calibration. When the Equalize timer expires, the charger will immediately return to Float mode. Equalize mode will restart again after 14 days. Mode 3 (Displayed as P3 ) Mode 3 is an automatic Equalize cycle that activates every 30 days. The length of the Equalize cycle is determined by the timer setting. The length of the timer is eight hours by default and can be changed via Customer Calibration. When the Equalize timer expires, the charger will immediately return to Float mode. Equalize mode will restart again after 30 days. Mode 4 (Displayed as P4 ) Mode P4 is an automatic Equalize cycle that is triggered when the battery experiences a sizeable discharge. When the DC voltage drops below the Low Voltage alarm threshold, and exceeds the Low Voltage alarm time delay, Mode 4 is activated. However, the Equalize timer will only start and run the charger in Equalize mode for the duration set in the Equalize menu after the charger has raised the battery voltage high enough to clear the Low Voltage alarm. When the Equalize timer expires, the charger will immediately return to Float mode. 7
4.0 Display Calibration In order to calibrate the display voltage and current to match the measured values, two small potentiometers are provided, located on the 225C display driver board. P1 potentiometer is used to calibrate the display voltage and P2 potentiometer is used to calibrate the display current. An LCD display contrast potentiometer (P3) is also provided for contrast adjustment. Please refer to Figure 5. NOTE: Adjusting the potentiometers mentioned will NOT change the output of the charger; only the display values will be changed. P3 LCD Contrast Calibration P1 (VCAL) Display Voltage Calibration P2 (ICAL) Display Current Calibration Figure 5 Display Calibration 8
Document Control and Revision History Part Number: 110313 Instruction Number: P25-LOPT46SERIES-1 Issue ECN: 16664 01/05 21360 03/17 19415 02/12 17195 06/06 16685 02/05 9