La Marche Manufacturing Company | www.lamarchemfg.com
Five Star Electric
Project: C-40455 MCH-Bus Depot
Instruction Manual for:
Battery Charger
Model # A12B-200-12V-C3-6L-01666
Battery Distribution Center
Model # BDC-200-12V-6-5FT
106 Bradrock Dr. Des Plaines 60018-19671
Tel: 847 299 1188
Fax: 847 299 3061
CPN 126144
Instruction Drawing Number: P25-LA12B/BDC-5STAR-1
i 19901
Revision A00 Rev. Date: 02/25 ECN:
i
Important Safety Instructions
Before using this equipment read all manuals and other documents related to this unit and other equipment
connected to this unit. Always have a copy of a units manual on file nearby, in a safe place; if a replacement
copy of a manual is needed it can be found at the www.lamarchemfg.com.
Electrical Safety
WARNING: Hazardous Voltages are present at the input of power systems.
The output from
rectifiers and from batteries may be low in voltage, but can have a very high current capacity that
may cause severe or even fatal injury.
When working with any live battery or power system, follow these precautions:
Never work alone on any live power system, someone should always be close enough to come to your aid
Remove personal metal items such as rings, bracelets, necklaces, and watches.
Wear complete eye protection (with side shields) and clothing protection.
Always wear gloves and use insulated hand tools.
WARNING: Lethal Voltages are present within the power system. Parts inside the unit may still be
energized even when the unit has been disconnected from the AC input power. Check with a meter
before proceeding. Do not touch any uninsulated parts.
A licensed electrician should be used in the installation of any unit.
Always disconnect the unit from the supply, batteries and loads before performing maintenance or cleaning.
If the unit is hot-swappable, simply remove it from the shelf for any maintenance or cleaning.
Always assume that an electrical connection is live and check the connection relative to ground.
Be sure that neither liquids nor any wet material come in contact with any internal components.
Do not operate this unit outside the input and output ratings listed on the unit nameplate.
Do not use this unit for any purpose not described in the operation manual.
Mechanical Safety
This unit or parts of the unit may get very hot during normal operation, use care when working nearby.
Do not expose equipment to rain or snow. Always install in a clean, dry location.
Do not operate equipment if it has received a sharp blow, been dropped, or otherwise damaged in any way.
Do not disassemble this unit. Incorrect re-assembly may result in a risk of electric shock or fire.
Battery Safety
WARNING: Follow all of the battery manufacturer’s safety recommendations when working with or
around battery systems. DO NOT smoke or introduce a spark or open flame in the vicinity of a
battery. Some batteries generate explosive gases during normal battery operation.
To reduce risk of arc, connect and disconnect the battery only when the unit is off.
If it is necessary to remove battery connections, always remove the grounded terminal from the battery first.
Remove personal metal items such as rings, bracelets, necklaces, and watches.
Always wear rubber gloves, safety glasses, and a rubber lined vest/apron when working near a battery.
Have plenty of fresh water and soap nearby in case the battery electrolyte contacts skin, clothing, or eyes.
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 seek medical attention immediately.
Do not drop metal on a battery. A spark or short-circuit could occur and could cause an explosion.
ii
Unit Location
Allow at least 6 inches of free air on all vented surfaces for proper cooling
Allow sufficient clearance to open the front panel for servicing.
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.
Never allow battery electrolyte to drip on this unit when reading the specific gravity or filling the battery.
Never place this unit directly above a standard flooded battery. Gases from the battery will corrode and
damage equipment.
A sealed maintenance free or valve regulated lead acid (VRLA) battery may be placed below this equipment.
Check for Damages
Prior to unpacking the product, note any damage to the shipping container. Unpack the product and inspect the
exterior of product for damage. If any damage is observed, contact the carrier immediately. Continue the
inspection for any internal damage. In the unlikely event of internal damage, please inform the carrier and
contact La Marche for advice on the risk due to any damage before installing the product. Verify that you have
all the necessary parts per your order for proper assembly.
CAUTION: Failure to properly file a claim for shipping damages, or provide a copy of the claim to La
Marche, may void warranty service for any physical damages reported for repair.
Returns for Service
Save the original shipping container. If the product needs to be returned for service, it should be packaged in its
original shipping container. If the original container is damaged/unavailable, make sure the product is packed
with at least three inches of shock-absorbing material to prevent shipping damage. La Marche is not
responsible for damage caused by improper packaging of returned products.
Inspection Checklist
Enclosure exterior and interior is not marred or dented.
There is no visible damage components.
All internal components are secure.
Printed circuit boards are firmly seated.
All hardware and connections are tight.
All wire terminations are secure.
All items on packing list have been included.
Handling
Equipment can be very heavy and/or 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.
iii
Table of Contents
Important Safety Instructions ....................................................................................................... ii
Electrical Safety ......................................................................................................................................... ii
Mechanical Safety ...................................................................................................................................... ii
Battery Safety ........................................................................................................................................... ii
Unit Location ............................................................................................................................................ iii
Check for Damages .................................................................................................................................. iii
Returns for Service ................................................................................................................................... iii
Inspection Checklist .............................................................................................................................. iii
Handling .................................................................................................................................................. iii
Manufacturer's Authorized Reps - Contact Info ............................................................................ 29
A12B Manual
1
Introduction – Equipment – system description ........................................................................2
1.1
Summary of Equipment Installed ................................................................................................... 2
1.2
Subcomponent Description ............................................................................................................ 2
1.3
Equipment Installation Location Plan .............................................................................................. 2
1.4
Performance/Mechanical Data ........................................................................................................ 2
1.5
Programming Parameters .............................................................................................................. 3
2
Sequence of Operation ..........................................................................................................3
3
Installation Procedures ..........................................................................................................3
4
3.1
Mounting the A12B ........................................................................................................................ 3
3.2
Making the AC Input Connections................................................................................................... 4
3.3
Making the DC Output Connections ................................................................................................ 4
3.4
Power Failure Relay ....................................................................................................................... 5
3.5
Shunt Trip .................................................................................................................................... 5
Service and Maintenance Manual ............................................................................................5
Recommended Service Time Intervals ....................................................................................................... 6
4.1
4.1.1
Troubleshooting ............................................................................................................................ 7
Diode Troubleshooting and Replacement .................................................................................... 8
5
Bill of Materials Listing ...........................................................................................................9
6
Recommended Spare Parts .................................................................................................. 14
7
As-built Drawings ................................................................................................................ 15
7.1
Wiring Diagrams - Factory and Field ..............................................................................................15
7.2
Dimension Drawing ......................................................................................................................16
Manufacturer's Guarantees and Warrantees................................................................................. 17
iv
BDC Manual
1
Introduction – Equipment – system description ...................................................................... 20
1.1
Summary of Equipment Installed ..................................................................................................20
1.2
Equipment Installation Location Plan .............................................................................................20
1.4
Performance/Mechanical Data .......................................................................................................20
2
Sequence of Operation ........................................................................................................ 20
3
Installation Procedures ........................................................................................................ 21
4
6
3.1
Mounting the BDC ........................................................................................................................21
3.2
Making the DC Input Connections .................................................................................................21
3.3
Connecting Multiple BDC units ......................................................................................................22
3.4
Making the DC Output Connections ...............................................................................................22
Service and Maintenance Manual .......................................................................................... 23
4.1
Recommended Service Time Intervals ...........................................................................................23
4.2
Troubleshooting ...........................................................................................................................23
As-built Drawings ................................................................................................................ 26
6.1
Wiring Diagrams - Factory and Field ..............................................................................................26
6.2
Dimension Drawing ......................................................................................................................27
v
La Marche Manufacturing Company | www.lamarchemfg.com
A12B
Constavolt® MagAmp Battery Charger
Unit shown with optional features
Installation and Operation Manual
1
1
Introduction – Equipment – system description
1.1
Summary of Equipment Installed
The La Marche model A12B series filtered battery chargers/power supplies are engineered for the demanding
requirements of Switch Gear applications, Process Controls and Communications. The magnetic amplifier
circuitry is designed to carry continuous and intermittent loads up to the maximum rated output. Its robust
design and unmatched reliability has made this workhorse the standard in the industry, and with its customizing
features, there is virtually no application that the A12B cannot meet.
1.2
Subcomponent Description
The A12B battery charger has four basic components: a transformer, saturable reactor, silicon rectifier stacks,
and control unit. The basic operation of these units is as follows:
The transformer transforms the incoming AC voltage to the required level to charge the battery. The
transformer also isolates the incoming power from the output. The saturable reactor regulates the power
output of the transformer continuously over the charge cycle. The rectifier stacks are made up of silicon diodes
rectify the secondary AC power to DC power. The control senses the condition of the battery and controls the
reactor, which in turn regulates the power output of the transformer.
The standard float charger is provided with a potentiometers for adjusting the float and equalizing voltage level
and a float/equalize switch for transferring the output of the charger from float charge to equalize charge.
1.3
Equipment Installation Location Plan
When installing the A12B allow at least 6 inches of free air on the top back and sides. In order to allow access
to the front panel and door for servicing, allow a minimum of three feet of free space in front of the charger.
1.4
Performance/Mechanical Data
ELECTRICAL
AC Input
480V +10% / -12% at 60Hz ± 5%
DC Output
200A at 12VDC
Output Filtering
100mV RMS, with or without battery
Regulation
± 0.5% from no load to full load over the specified input voltage, frequency
and ambient temperature range.
Meters
DC Ammeter & DC Voltmeter ± 2% Accuracy
PROTECTION
Current Walk-In
The output current will gradually increase after the charger is turned on,
eliminating surges and overshoot
Current Limit
50 - 120% of the rated DC output current.
AC Protection
3 Pole AC breaker
DC Protection
Positive Leg DC fusing
Emergency Restoration
The battery charger may be connected to a battery which is heavily discharged
and recharge it without clearing any protective devices.
MECHANICAL/ENVIROMENTAL
Dimensions
27” Width | 23.5” Depth | 44.5” Height
Approximate Weight
495 lbs. (225 kg)
Operating Temperature
32 to 122˚F (0 to 50˚C)
Storage Temperature
-40 to 185° F (-40 to 85° C)
Relative Humidity
0 to 95% (non-condensing)
2
1.5
Programming Parameters
The factory settings of the A12B are based on the customer order, unless otherwise specified all units are set at
the factory with the following settings.
Float Voltage:
Equalize Voltage:
Current Limit:
2.17 Volts/Cell (V/C) for Lead Acid (LA)  13 VDC
2.33 Volts/Cell (V/C) for Lead Acid (LA)  14 VDC
115% or nominal output current  230ADC
Check the battery manufacturer’s specification for the proper float, equalize voltage setting and equalize cycle.
2
Sequence of Operation
To prevent the DC fuse from blowing when connecting the battery, connections should be done in the following
order.
1.
2.
3.
4.
Make sure that the incoming power to the unit is turned off.
Connect AC input line to the unit’s input terminals as described in Section 2.3.
Connect the negative battery cable to the unit’s DC output terminals. OBSERVE PROPER POLARITY.
Energize the charger by turning on the unit AC breaker. This will charge the capacitors inside the unit and
eliminate heavy arcing when the battery is connected.
5. After about 30 seconds, turn off the AC power and immediately connect the remaining battery cable.
6. Connect the DC loads. OBSERVE PROPER POLARITY.
7. Turn on the charger again and the charger will commence charging the batteries and powering the load.
3
Installation Procedures
3.1
Mounting the A12B
When mounting the A12B, consider the size and weight of the unit. The floor must be able to support the
weight of the unit as well as an additional safety factor. The location chosen for the charger should be within
an ambient temperature range of 32 to 122˚F (0 to 50˚C) with a non-condensing relative humidity no higher
than 95%. The A12B should be mounted in an area free of explosive materials and away from drips and
splatter. The A12B utilizes convection cooling so a clearance of at least 6in of free air must be maintained on
the top and both sides for cooling air. Maintain at least 36in or more of clearance at the front of the charger in
order to allow for operation and maintenance.
Floor-Mounting Procedure
The floor-mount brackets for each charger are preinstalled at the factory. To floor-mount the A12B, install four
3/8” bolts into the floor (spaced according to the figure below). Place the A12B on the bolts, add appropriate
mounting hardware, and tighten securely.
A
25.750
B
17.500
Bolt Size 3/8”
# Bolts
4
3
3.2
Making the AC Input Connections
Before making any connections to the A12B ensure that the AC
Power is off at the main breaker box and that the unit’s AC breaker
is off. Check that the source voltage and frequency matches the
voltage and frequency listed on the charger nameplate. The
minimum recommended wire size used for AC connection and
equipment ground is 12AWG. Always adhere to all National and
Local Wiring codes.
AC Connection Procedure
First connect an adequate earth ground lead to the unit ground
stud using a ¼” lug. Run the input AC wiring to terminals for AC
input in the enclosure. The maximum wire gauge accepted by the
AC terminals is 8AWG. To make these connections, strip the
insulation on the incoming wires about 0.4 inches and connect the
wires to the appropriate terminals. Using a flat-head screwdriver,
securely tighten the compression screws on the terminals.
AC Input Connections
3.3
Making the DC Output Connections
Before making any of DC output connections make sure you have read and fully understand the DC Connection
Procedure below. The minimum recommended wire size used for DC connection and is 4/0AWG. A 5/16” lug
should be used for the DC Wiring.
DC Connection Procedure
To prevent the DC fuse from blowing when connecting
the battery, connections should be done in the following
order.
1. Make sure that the incoming power to the unit is
turned off.
2. Connect AC input line to the unit’s input terminals as
described in Section 2.3.
3. Connect the negative battery cable to the unit’s DC
output terminals. OBSERVE PROPER POLARITY.
4. Energize the power supply by turning on the AC
power. This will charge the capacitors inside the unit
and eliminate heavy arcing when the battery is
connected.
5. After about 30 seconds, turn off the AC power and
immediately connect the remaining battery cable.
6. Connect the DC loads. OBSERVE PROPER
POLARITY.
7. Turn on the power supply again and the charger will
commence charging the batteries and powering the
load.
DC Output Connections
4
3.4
Power Failure Relay
This A12B is equipped with a power failure relay providing one set of form C contacts, for external alarm
connection. The power failure relay will de-energize when the AC power to the unit is lost. A terminal strip is
provided for ease of connection. The terminal strip accepts #6 lugs.
3.5
Shunt Trip
This A12B is equipped with a shunt trip in the AC breaker. The shunt trip allows the customer to connect a
circuit to remotely trip the breaker. A terminal strip is provided for ease of connection. The terminal strip
accepts #6 lugs.
Power Failure Relay
Connections
Shunt Trip
Connections
Power Failure/Shunt Trip Connections
5
4
Service and Maintenance Manual
Recommended Service Time Intervals
The A12B is designed to require little maintenance; however the A12B can be opened up by the customer for
maintenance. Before removing the front cover the AC breaker of the charger and all battery breakers must be
switched off.
The A12B has no moving parts, and all components are chosen having a near indefinite lifespan. Should a
component prematurely fail, a replacement can be ordered by contacting the factory.
The recommended routine maintenance schedule is listed below
Yearly
1.
2.
3.
4.
Blow out rectifier/inverter 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.
4th Year
REPEAT ABOVE WITH THE ADDITION OF:
1. Check relay contacts for pitting or corrosion.
2. Check capacitors for leakage.
7th Year
REPEAT ALL, WITH THE ADDITION OF:
1. Filter capacitors and resonating capacitors should be replaced.
10th Year
REPEAT ALL WITH THE ADDITION OF: (except replacing capacitors, they should be replaced every 7 years)
1. Check magnetics, components and wiring for signs of excessive heat.
6
4.1
Troubleshooting
SYMPTOM
POSSIBLE CAUSE
PROCEDURE
Open AC input fuse
1. Incorrect AC input
1.
Compare AC input voltage with voltage on
unit's nameplate.
2. Shorted diodes
2.
See "Diode troubleshooting and Replacement"
1. Defective or wrong voltage battery
1.
Compare battery voltage with unit nameplate.
2. Shorted connector
2.
Check with volt-ohmmeter
3. Shorted or reverse output
3.
Check with volt-ohmmeter
4. Shorted diodes
4.
See "Diode troubleshooting and Replacement"
1. Defective power failure relay
1. Measure voltage from Pin 5 on control panel to
negative DC output terminal. If voltage is zero, the
power failure relay may be defective.
2. Defective control panel
2. To check control panel on units (without a power
stage) turn off unit and disconnect 12 Pin
connector from AC41-2 or S2A-340S Circuit Board,
jump Pin 3 to 8 on connector. Power up unit if unit
goes to high rate, electronic panel may be
defective.
Open DC output
fuse
Charger operates,
but will not charge
battery
Units with Power Stage (AC7), disconnect 12 Pin
connector, power up unit.
Charger will not
taper to finish rate
3. Open float/equalize potentiometer
3. Check continuity of float/equalize potentiometer
with volt-ohmmeter. An open circuit from its slider
to the control Pin 2 will cause low unit output.
4. Shorted transistor on power stage
AC7
4. Remove power transistors from heatsink and
check with ohmmeter. A shorted transistor will
cause low unit output.
1. Defective battery
1. Check for defective cells in battery.
2. Defective electronic panel
2. Jump center coil on saturable reactor if unit runs
low; problem may be control panel.
3. Open float/equalize potentiometer
or switch
3. Check continuity offloat/equalize potentiometer
and float/equalize switch. An open switch or
potentiometer may cause the unit to run high than
normal.
7
4.1.1
Diode Troubleshooting and Replacement
The silicon diode may be a source of trouble. The function of the diode is to allow the flow of current through it
in one direction only. If the polarity of the conducting current is reversed, the diode will block the current flow.
Thus, the diode has a low resistance to current flow in one direction, and a high resistance to current flow in
the other direction. Therefore, a simple ohmmeter may be used to test the diode. The procedure for checking
the silicon diode is as follows:
1. Isolate one end of the diode by disconnecting the wires attached to the nipple (or pigtail) end of the
diode (only one end of the diode must be disconnected).
2. Clip one lead of the ohmmeter to the nipple (or pigtail) lead of the diode. Clip the other ohmmeter lead
to the aluminum heatsink (if a portable multimeter is used, set the switches on ohms, DC and scale
RX100).
3. Note the ohmmeter reading, then reverse the leads to the diode. Again, note the ohmmeter reading.
If the diode is good, the meter will indicate a high resistance in one direction, and a low resistance with
the leads reversed. If the diode is shorted, the meter will read full scale, or "0" resistance with the
leads in either direction. If the diode is "open", the ohmmeter needle will not indicate or show infinite
resistance, indicating an open circuit with the ohmmeter leads in either direction.
4. All diodes must be checked in the event that more than one diode is defective.
5. If the diode is defective, remove the defective diode from the heatsink and replace with a new diode.
When installing a new diode, be sure to note if the old diode was insulated from the heatsink. If the
diode should be insulated from the heatsink, care should be taken so that the mica insulating washer is
placed properly on each side of the heatsink with insulating bushing between the diode mounting stud
and the aluminum heatsink.
WHEN ORDERING REPLACEMENT PARTS, SCHEMATICS, OR REQUESTING SERVICE INFORMATION,
ALWAYS GIVE MODEL NUMBER, SERIAL NUMBER AND AC INPUT VOLTAGE.
8
5
Bill of Materials Listing
Part.Number
Quantity Ref Designator
Li# Description........................ Unit.Meas Notes....................
1 102328
1G1F3-01011-A-57
CHOKE
3PHASE
1.0000
EA
2 35556
1G3D1-03215-A-35555
PT (A11-200-12V-C3) 6L
3.0000 PT
EA
3 35557
1G3D2-02012-B-35555
SR (A11-200-12V-C3) 6L
3.0000 SR
EA
4 58251
AC41-2-20
CTL. PL. W/CUR. LMT. 12V
1.0000
EA
5 51679
AC52-1-4
CONTROL PNL. BOOST SUPPLY
1.0000
EA
6 64616
AC7-D1-03
TRANSISTOR POWER STAGE
1.0000
EA
7 107170
H12-72-19-3
Wiring Harness
72 Case
1.0000
EA
8 113275
H12-72AC-3CT-3BEGG-10
Wiring Harness
72 Case
1.0000
EA
9 63382
P11GW-0109-4N12N
TERMINATION BASE
COMPONENT
1.0000 DC
EA
10 11472
P12H-CAUTN-0401U2
BATTERY CONNECTION
CAUTION
1.0000
EA
9
11 11479
P12H-WARNG-0201U2
WARNING LABEL ADHESIVE
BACKING WITH WHITE
1.0000
EA
12 11718
P146-2
2" CAP MOUNTING BRACKET
3 MTG LEGS ZINC FINISH
1.0000
EA
13 11779
P14T-AJ1-CBD/A
CONTROL TRANSFORMER 50VA
50/60HZ. PRIMARY VOLTS
1.0000 CT
EA
14 12262
P15-F19
BUS BAR - 600A
1.0000
EA FOR DC BLOCK
15 88838
P15-F435A
CAP TRAY #27,70,72 CASE
PAINTED ANSI-61 GREY
1.0000
EA
16 12635
P15-F94A
19 CASE RESIS. MTG.
RAIL-AG
1.0000
EA
17 13223
P16R-AP120-2R5
RELAY, 120VAC WITH (1)
FORM "X" AND (1) FORM "C"
1.0000 PF
EA
18 14205
P1DA-M300-B13S
DC AMMETER (0-300) 2%
HIGH
1.0000 A
EA
19 14369
P1DV-M20-B5S
DC VOLTMETER (0-20) 2%
HIGH TORQUE, 3 1/2" PANEL
1.0000 V
EA
20 14489
P1S-E300-A50M
AMMETER SHUNT 300 AMP 50
MV AMMETER SHUNT (TYPE A)
1.0000 S
EA
21 40610
P25-LSAA12-1-B
SPL.ADDENDUM INST FOR A12
MANUAL W/ACC
1.0000
EA
22 15019
P2A-150-1.9KA2
CAP,150VDC,1.9KMFD,2"D X
4-1/8"H CAPACITOR TYPE
1.0000 C2
EA
10
23 41826
P2A-75-64KH3
CAPACITOR 75VDC 64KMFD
2.5"D-5.625"H
3.0000 OC
EA
24 101233
P3-72-A18A
72 CASE SPCL NO METER PNL
W/ P3-16-R02A RAIL
1.0000
EA
25 113283
P3-72-F65A-S1
#72 CASE FRONT PANEL A12B
ACB-3P-EHD, S2A-199 W/OPT
1.0000
EA
26 15625
P3-8-R06A
MOUNTING RAIL, ANSI 61
GRAY
8.0000
EA FOR CHOKE, CAP, MAGNETICS
BLOCKING DIODE
27 16519
P3-47-R02A
HEATSINK MTG. RAIL - A.G.
PER DRAWING P3-47-R02X,
2.0000
EA FOR HEATSINK
28 111473
P4-WEHD-15A3K
CKT BKR 3 POLE 15 AMP
W/120VAC SHUNT TRIP COIL
1.0000 ACB
EA
29 18951
P5A-EMA-B1
MODULAR TERMINAL BLOCK
END
1.0000
EA
30 19006
P5B-20H-8B8B
BARRIER TERMINAL STRIP 8
1.0000
EA FOR AC POWER FAILURE
ALARM CONTACTS,SHUNT TRIP
SIDE OF CASE PREPUNCHED
FOR 8 PIN STRIP
31 19095
P5E-44E-6A1T
MODULAR TERMINAL BLOCK,
3PT, 30AMP MAX. THIS
1.0000
EA
32 20073
P6M-200F-25V
RESISTOR 200 WATT 25 OHM
VAR.
1.0000 RC
EA
33 20171
P6M-50C-50B
RESISTOR 50 WATT 50 OHM
10% FIX. FIXED RESISTOR
1.0000 RL
EA
11
34 21071
P8-A1-A250
FUSE (AT) 130V 250A
1.0000 DCF
EA
35 104815
PCA-70/72-1
PACKAGING KIT
#70, 72 CASE
1.0000
EA
36 39846
S1E-1D75-0103
HEATSINK ASSY. EXT. 1DF
275F2
1.0000
EA FOR SD6
37 28579
S1F-17E0-2604
HEATSINK ASSY. 2D F/R
275F2 3PH2
2.0000
EA FOR SD1 SD2
38 28578
S1F-17E0-2605
HEATSINK ASSY. 2D F/R
275F2 3PH1
1.0000
EA FOR SD1 SD2
39 27390
S2A-199-0103
A11/A12 ADJUSTMENT
PCB-12V
1.0000
EA
40 23041
S2C-47A-A3
SURGE PROTECTOR ASSY.
1.0000 DCSP
EA
41 23090
S2C-47B-B2
SURGE PROTECTOR ASSY.
1.0000 SP
EA
43 126100
S4H-3-2.5D-7.25H-2
CAP BUS BAR KIT
3-2.5"D X 7.25"H 225A
1.0000
EA FOR OC
44 42706
S4R-200W-2
KIT MTG (1) 200W RES
BRKT W/MTG SLOT 12.50"ROD
1.0000
EA FOR RC
45 39548
S4R-50W-1
KIT FOR MOUNTING 50 WATT
RESISTOR
1.0000
EA FOR RL
12
Drawing Numbers: E1029-1187
*
D72
*
P3-72-P01X
(3of3)
*
P15-F435X
(2of2)
*
S4A-14-1A1E
(1of8)(6of8).TIF
*
13
6
Recommended Spare Parts
Part.Number........................ Description.............. Qty...... UM Level
58251
AC41-2-20
CTL. PL. W/CUR. LMT. 12V
1.0000 EA
A
64616
AC7-D1-03
TRANSISTOR POWER STAGE
1.0000 EA
A
21071
P8-A1-A250
FUSE (AT) 130V 250A
1.0000 EA
A
27390
S2A-199-0103
A11/A12 ADJUSTMENT
PCB-12V
1.0000 EA
A
14
7
As-built Drawings
7.1
Wiring Diagrams - Factory and Field
Schematic
15
7.2
Dimension Drawing
16
Manufacturer's Guarantees and Warrantees
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
one year from date of purchase. In addition to the standard one (1) year warranty, La Marche warrants its magnetics and
power diodes on a parts replacement basis only for nine (9) more years under normal use.
Any part or parts of the equipment (except protective devices, DC connectors and other wear-related items) that prove
defective within a one (1) 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. Magnetics and power
diodes are warranted for ten (10) years after date of purchase. During the last nine (9) years of this ten (10) year warranty
period, the warranty covers parts replacement only, no labor or other services are provided by La Marche, nor is La Marche
obligated to reimburse the owner or any other person for work performed.
Should a piece of equipment require major component replacement or repair during warranty period, these can be handled
in one of three ways:
1.
If the Purchaser elects to take the responsibility of repairing the equipment and requests replacement part(s),
Purchaser or Sales Representative must contact Factory for return authorization and a purchase order must be issued.
Replacement part(s) will be promptly shipped and invoiced. After the defective part(s) are returned and inspected at the
Factory, if the defect(s) were due to faulty material or workmanship, credit will be issued.
2.
The equipment can be returned to the La Marche factory to have the inspections, 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 year. If the Extended
Warranty is purchased, the parts required for repair will also be at no cost but La Marche will notify the Purchaser of the
costs of Labor to replace the defective part(s). A Purchase Order to cover this labor is required before repairs will be
initiated. Transportation charges or duties shall be borne by Purchaser.
3.
If the purchaser elects not to return the equipment to the factory and wishes a factory service representative to
make adjustments and/or repairs at the equipment location, La Marche's field service labor rates will apply. A purchase
order to cover the labor and transportation cost is required prior to the deployment of the service representative.
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 La Marche 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, OR 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.
17
18
La Marche Manufacturing Company | www.lamarchemfg.com
BDC
Battery Distribution Center
Installation and Operation Manual
19
1
Introduction – Equipment – system description
1.1
Summary of Equipment Installed
La Marche Battery Distribution Center (BDC) provides quick, easy and flexible means of distributing battery
charging current to multiple batteries simultaneously. Ideal for maintenance facilities such as commuter bus and
trains, that requires heavy-duty rugged construction throughout to handle extreme conditions.
This BDC can be configured for 2, 4 or 6 batteries. Expansion kits are available for future expansion. Internal
common copper bus is 200amp rated for maximum continuous current rating. Standard system configuration
includes a breaker for an on/off switch and DC ammeter. A charging pilot led and industries first reverse polarity
indicator with sonalert to indicate improper connection. For added safety measures the BDC includes heavy-duty
insulated covers for battery clips are standard.
1.2
Equipment Installation Location Plan
The La Marche Battery Distribution Center (BDC) is designed to be wall mounted above a battery charging
center. The BDC should be mounted at a height approximately 4.5 feet above the batteries to avoid putting
stress on the battery leads. The BDC should be mounted as close as possible to the DC source.
1.4
Performance/Mechanical Data
ELECTRICAL
DC Input
12VDC at up to 200A
Meters
DC Ammeter ± 2% Accuracy
PROTECTION
AC Protection
100 Amp 1 Pole DC breaker
MECHANICAL/ENVIROMENTAL
Dimensions
27” Width | 23.5” Depth | 44.5” Height
Operating Temperature
32 to 122˚F (0 to 50˚C)
Storage Temperature
-40 to 185° F (-40 to 85° C)
Relative Humidity
0 to 95% (non-condensing)
2
Sequence of Operation
The BDC is equipped with a yellow “Charging” indicator that is lit whenever the battery breaker is closed. If the
yellow indicator is lit that terminal is live and extreme caution must be observed.
When adding or removing a battery make sure that the corresponding battery breaker has been switched off.
Connect the black clip to the negative of the battery and the red clip to the positive of the battery. Once the
battery is connected the breaker can once again be switched on.
When no battery is connected the corresponding battery breaker should always be off.
Under normal operation batteries can be swapped in and out of the BDC without needing to shut down the
connected charger.
20
3
Installation Procedures
3.1
Mounting the BDC
When mounting the BDC, consider the size and weight of the unit. The wall must be able to support the weight
of the unit as well as an additional safety factor. The location chosen for the charger should be within an
ambient temperature range of 32 to 122˚F (0 to 50˚C) with a non-condensing relative humidity no higher than
95%. The BDC should be mounted in an area free of explosive materials and away from drips and splatter. The
BDC utilizes convection cooling so a clearance of at least 6in of free air must be maintained on the top and both
sides for cooling air. Maintain at least 36in or more of clearance at the front of the unit in order to allow for
operation and maintenance.
Wall-Mounting Procedure
To wall-mount the BDC, install two 5/16” bolts into the wall spaced 50.625” apart. Place the BDC on the bolts,
add appropriate mounting hardware, and tighten securely. Install the remaining four bolts for additional
security.
3.2
Making the DC Input Connections
The wire used for the input BDC must be sized appropriately for the system. The wire size should be
determined by the output breaker of the battery charger, with a minimum wire size of 2 AWG. When
connecting the output of the charger to the input of the BDC, make sure the DC leads are as short as possible.
La Marche recommends that conduit be used.
WARNING: ALWAYS observe proper polarity when making DC connections. Connect the positive
(+) output of the charger to the positive (+) input of the BDC and connect the negative (-) output of
the charger to the negative (-) input of the BDC.
DC Connection Procedure
Before making any connections make sure that both the AC and DC breakers (fuses) of the charger are off
(open). ALWAYS observe proper polarity when making DC connections. Connect the positive (+) output of the
charger to the positive (+) bus bar of the BDC and connect the negative (-) output of the charger to the
negative (-) bus bar of the BDC.
DC Connections
21
3.3
Connecting Multiple BDC units
To connect multiple BDC units together, connect the positive bus bar of one BDC to the positive bus bar of the
other. Connect the negative bus bar of one BDC to the negative bus bar of the other. The wires used for the
interconnection of BDC must be adequately rated and run through conduit.
Connect DC Positive Bus of BDC #1 to DC Positive Bus of BDC #2
Connect DC Negative Bus of BDC #1 to DC Negative Bus of BDC #2
3.4
Making the DC Output Connections
When adding or removing a battery make sure that the corresponding battery breaker has been switched off.
Connect the black clip to the negative of the battery and the red clip to the positive of the battery. Once the
battery is connected the breaker can once again be switched on.
Battery #1 Positive
Battery #1 Negative
Battery #2 Positive
Battery #2 Negative
When no battery is connected the corresponding battery breaker should always be off.
22
4
Service and Maintenance Manual
4.1
Recommended Service Time Intervals
The BDC is designed to require little to no maintenance, however the BDC can be opened up by the customer
for maintenance. Before removing the front cover the DC breaker of the charger and all battery breakers must
be switched off.
The BDC has no moving parts, and all components are chosen having a near indefinite lifespan. Should a
component prematurely fail, a replacement can be ordered by contacting the factory.
Every couple of months the BDC should be opened up for a visual inspection. All connections should be
checked for tightness and tightened if necessary. If needed a dry air hose can be used to blow dust out of the
BDC.
The recommended routine maintenance schedule is listed below
Yearly
5.
6.
7.
8.
Blow out BDC enclosure 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.
4.2
Troubleshooting
Troubleshooting should be performed only by trained service personnel or experienced electricians. Before
setting up any complicated testing or jumping to any conclusions, give the unit a general inspection.
Check DC input/output cables, connections, and battery charger operation. If the problem s found to be in the
battery charger, refer to the charger’s manual for troubleshooting procedures.
NOTE: When ordering replacement parts, drawings, or schematics, always give model number and serial
number.
Symptom
Possible Cause
No DC current or Intermittent current
Incorrect, Damaged or Loose Connections
No AC Voltage Applied to Battery Charger
Charger AC and/or DC Breaker Opened
Troubleshooting on Battery Charger Necessary
Ammeter reading incorrect or no current
Incorrect, Damaged or Loose Connections
Defective Ammeter (Replace as necessary)
Battery is charging but the Indicator does not
light
Defective Indicator (Replace as soon as possible)
Sonalert alarm sounds
Battery is connected incorrectly (the poles are reversed).
Immediately check and correct battery connection.
Battery Breaker trips
Shorted Battery
Battery connections reversed
Defective Breaker (Replace as necessary)
23
5
Bill of Material
Part.Number
Quantity Ref Designator
Li# Description........................ Unit.Meas Notes....................
1 125232
P3-BDC-A01A
COMPLETE CASE FOR 6
TERMINAL BDC ANSI-GREY
1.0000
EA
2 125137
P25-LBDC-1
INSTRUCTION MANUAL FOR
BATTERY DISTRIBUTION
1.0000
EA
3 14061
P1DA-E100-A1S
DC AMMETER (0-100) 5%
EMICO MODEL 44 (E1) IRON
6.0000 A
EA
4 125152
P10-SAA-YQ
LAMP/SOCKET ASSY.
6-13.5VAC, 10-20VAC
6.0000 DCL
EA
5 125153
P10-SAA-RQ
LAMP/SOCKET ASSY.
6-13.5VAC, 10-20VAC
6.0000 RPL
EA
6 18353
P4-HAM-100B1A
CIRCUIT BREAKER 1P,100A
6.0000 DCB
EA
7 29514
S2C-47B-GB02
DIODE ASSEMBLY - 1A. 800V
3.0000 SD2
EA
8 125147
S2C-47B-FA08
RESISTOR/DIODE ASSEMBLY,
2K OHM, 1/4WATT
1.0000 SD1/R1
EA FOR SA
9 52114
P10-A24D-0EV
ELEC. SIGNALLING DEVICE,
6-28V
1.0000 SA
EA
10 125238
SP80-2-5
DC CABLE ASSEMBLY
5 FOOT CABLE
11 20841
P7NB-6
NYLON STRAIN RELIEF
BUSHING NYLON STRAIN
6.0000
EA
12.0000
EA
24
12 125098
P15-U202
COPPER BUS BAR
FOR BDC
6.0000
EA
13 125230
P15-U203
COPPER BUS BAR
CONNECTOR FOR BDC
4.0000
EA
14 20839
P7NB-4
NYLON SNAP BUSHING, .875"
MTG. HOLE NYLON
15 20861
P7PB-BP-1.093
PLUG BUTTON 1.093-1.125
BLK
12.0000
EA
2.0000
EA FOR MIDDLE AND RIGHT BASE
Drawing Numbers: E-BDC-1
*
D-BDC6
(2 SHEETS)
*
ABDC-1
*
25
6
As-built Drawings
6.1
Wiring Diagrams - Factory and Field
Schematic
26
6.2
Dimension Drawing
27
Manufacturer's Guarantees and Warrantees
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
one year 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 one 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 major component replacement or repair during the warranty period, these can be
handled in one of two ways:
1. The equipment can be returned to the La Marche factory to have the inspections, 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 year. Transportation charges or duties shall be
borne by purchaser.
2. If the purchaser elects not to return the equipment to the factory and wishes a factory service
representative to make adjustments and/or repairs at the equipment location, La Marche's field service
labor rates will apply. A purchase order to cover the labor and transportation cost is required prior to
the deployment of the service representative.
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.
28
Manufacturer's Authorized Reps - Contact Info
La Marche Manufacturing Company
106 Bradrock Drive
Des Plaines, IL 60018
Phone: 847-299-1188
Fax: 847-299-3061
Regular Business Hours are Monday through Friday from 8AM – 5PM (CST)
Service Department
Marius Hetrea
Bardomiano Nava
Karen Hughes
Service Manager
Service Technician
Support Coordinator
Ext. 358
Ext. 430
Ext. 313
Applications Engineering Manager
Application Engineer
Application Engineer
Parts/Application Engineer
Ext.
Ext.
Ext.
Ext.
Sales Department
Don Henry
Al Patel
Jose Rolon
Ken Cichanski
314
351
407
316
After hours emergency service number: 847-296-8939
Please call this number outside of our regular business hours ONLY!
29