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La Marche Manufacturing Company | www.lamarchemfg.com
ULTRA SERIES
CHARGER
Installation and Operation Manual
106 Bradrock Dr. Des Plaines 60018-1967 CPN 134372
Tel: 847 299 1188 Fax: 847 299 3061
Instruction Drawing Number: P25-LUSC-1
Revision A03 Rev. Date: 02/17 ECN: 21367
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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:
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:
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:
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 the 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 lead to an explosion.
Hazardous Voltages are present at the input of power systems. The output from
Lethal Voltages are present within the power system. Parts inside the unit may still be
Follow all of the battery manufacturer’s safety recommendations when working with or
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Unit Location
Allow at least 6 inches of free air on all vented surfaces for proper cooling
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:
Marche, may void warranty service for any physical damages reported for repair.
Failure to properly file a claim for shipping damages, or provide a copy of the claim to La
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 are no visibly damaged 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
Use caution handling the unit to prevent damage.
Precautions
● Do not connect battery and Ultracap in parallel.
● Do not operate this system in direct sunlight, in contact with fluids, or where there is excessive dust or
humidity.
● Be sure the air vents on the system are not blocked. Allow adequate space for proper ventilation.
● Connect the charger AC Mains power cable directly to the distribution panel. Use cables according to
the size of the upstream AC protection panel device.
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Table of Contents
Important Safety Instructions ................................................................................................................... ii
Table of Contents ..................................................................................................................................... iv
1. Ultra Series Charger General Description ............................................................................................ 5
Standard Features .................................................................................................................................. 5
Table 1 – Front Panel Overview ............................................................................................................... 5
2. Installation ............................................................................................................................................ 6
2.1 Where to Install .......................................................................................................................... 6
2.2 Mounting .................................................................................................................................... 6
3. Electrical Connections .......................................................................................................................... 6
3.1 Input AC Connections ............................................................................................................... 7
3.2 Output DC Connections ............................................................................................................ 7
3.3 Power Cabling Guide ................................................................................................................ 8
Table 2 - Recommended Wire Size table ................................................................................................. 8
Table 3 - Wire Size/Area table ................................................................................................................. 8
3.4 Alarm Connections .................................................................................................................... 9
Table 4 - Alarm Relay Logic .................................................................................................................... 9
4. Temperature Compensation ................................................................................................................ 10
5. Operation ............................................................................................................................................ 11
5.1 Front Display Panel .................................................................................................................... 11
5.2 Initial Set-Up .............................................................................................................................. 12
5.3 User Menu ................................................................................................................................. 13
6. Troubleshooting .................................................................................................................................. 14
7. Technical Specifications .................................................................................................................... 15
Document Control and Revision History ....................................................................................... 16
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1. Ultra Series Charger Description
General Description
The La Marche Ultra Series charger is a high performance charger, which utilizes high frequency
technology. It is specially designed to meet the requirements of charging ultra capacitors, as well as to
charge the batteries used in Engine starting applications. The charger provides protection against
battery reverse connection, high DC voltage, input voltage variation and surges. This system is
intended for indoor use only.
Standard Features
• Power Factor corrected high frequency charging technology
• Wide AC input range (105-264 VAC 45-65 Hz)
• Galvanic Isolation from AC to DC
• LCD Digital Voltmeter & Ammeter
• Adjustable Current Limit from 50-105%
• Alarm relay contacts for:
- Charger Fail
- AC Fail
- Low DC voltage
Figure 1 – ULTRA SERIES CHARGER Display
- High DC Voltage
- Summary alarm
• Operating Temperature: -40°C to 65°C (-40°F to 149°F)
Storage Temperature: -40°C to 85°C (-40°F to 185°F)
• Battery continuity Test (Manual and Auto mode)
• Automatic High battery cutout
• Soft Start feature
• Over Temperature and Over Voltage protection.
• Complies with NFPA 110
Symbol Color Description
AC ON Green Indicates that correct AC voltage is present in the Rectifier
FLOAT Green Indicates charger is running in floating mode.
EQ Yellow Indicates charger is running in equalize mode.
FAULT Red Indicates any fault condition
Table 1 – Front Panel Overview
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2. Installation
g
2.1 Where to Install
The charger should be installed in a location that meets the following requirements:
1. Never install the equipment near liquids or in an excessively damp environment.
2. The charger must be installed in a room with proper ventilation.
3. Avoid using equipment in location with corrosive gases (e.g. over flooded Lead Acid batteries) and dust.
2.2 Mounting
The ULTRA SERIES CHARGER is desi
ned with
simple installation in mind. The charger is wall
mountable using four #10 bolts. To mount the
Ultra series charger on the wall, mark the drill
points on the wall per the mounting dimensions
shown in Figure 2. Install the anchors on the 4
marked spots. Place the unit on the wall to
match the mounting holes with anchor spots.
Install four #10 bolts on the wall using
appropriate mounting hardware.
Refer to figure 2 for mounting dimensions.
Figure 2 –Mounting Dimensions
After the Ultra series charger is mounted, the input, output and alarm connections can be made.
3. Electrical Connections
Unscrew the front cover to access the Input, Output and Alarm connectors. See the Figure 3 and Figure 4 in
section 3.1 and 3.2 on the next page for reference.
CAUTION : All wiring must be performed by a qualified personnel.
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3.1 Input AC Connections
Connect AC wiring to the equipment per the image shown below. Refer to section 3.3 for recommended wire
sizes.
3.2 Output DC Connections
Figure 3 – Input Connections
Connect Ultracap/battery DC cables to the equipment per the image shown below. Refer to section 3.3 for
recommended wire sizes.
Note: Verify that the connections are tight by tugging on the wires.
Note:
CAUTION:
charger is connected to the positive battery terminal and the negative terminal is connected to the
negative battery terminal
All National and local wiring codes must be followed. Wire insulation must be rated 90C or higher.
When connecting the DC cables to the battery, be certain the positive terminal of the
Figure 4 – Output Connections
.
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3.3 Power Cabling Guide
Use the following formulas and tables to determine proper wire size for minimal voltage drop.
Table of Conventions
CMA = Cross section of wire in circular MIL area
A = Ultimate drain in amperes
LF = Conductor loop feet
MaxAmp = Maximum allowable amperes for given voltage drop
AVD = Allowable voltage drop
K = 11.1 for commercial (TW) copper wire (KS5482-01)
= 7.4 for aluminum (KS20189)
DC Wire size requirements
Table 2 – Recommended wire size Table
Output
Current Rating
10A #14
20A #12
30A #10
40A #8
Recommended
wire size (AWG)
SIZE
(AWG)
18 1620 6 26240
16 2580 4 41740
14 4110 3 52620
12 6530 2 66360
10 10380 1 83690
8 16510 0 105600
Table 3 - Wire Size/Area Table
AREA
CIR.MILS
SIZE
(AWG)
Calculating Wire Size Requirements Calculating Current Carrying Capacity of Wire
KLFA
CMA
AVD
MaxAmp
AVDCMA
KLF
Note: AC wiring terminals can accept wire up to 12 AWG;
DC wiring terminals can accept wire up to 10 AWG;
Alarm wiring terminals can accept wire up to 16 AWG.
AREA
CIR.MILS
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3.4 Alarm Connections
The Ultra series charger is equipped with a
single set of Form C dry type relay contacts
(30V DC & 2A) for each alarm.
The charger has 5 different alarm relays.
Charger Fail
AC Fail
Low DC Voltage
High DC Voltage
Summary alarm
Refer to Table-4 for alarm relay wiring and
logic information.
Refer to image on the right for using proper
tool to make the alarm connections.
Installing dry contacts signal cables
1 – White Contact plate; 2- Dry Contact
Alarm Relays Logic
Figure 5 – Alarm Connections
ALARM PIN # CONTACTS ALARM RELAY LOGIC
CHARGER FAIL 4/5/6 NC/C/NO DE-ENERGIZE ON FAIL
AC FAIL 7/8/9 NC/C/NO DE-ENERGIZE ON FAIL
LOW DC VOLTAGE 10/11/12 NC/C/NO DE-ENERGIZE ON FAIL
HIGH DC VOLTAGE 13/14/15 NC/C/NO ENERGIZE ON FAIL
SUMMARY ALARM 16/17/18 NC/C/NO DE-ENERGIZE ON FAIL
Table 4 – Alarm Relay Logic
INPUT/OUTPUT PROTECTION:
AC Input Fuses: The Ultra Series charger is equipped with two AC input fuses.
DC Output Fuse: The Ultra Series charger is equipped with one DC output fuse.
Refer to unit specifications (Section 7) for fuse size information.
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4. Temperature Compensation
T
Ultra Series charger is equipped with an External Temperature Compensation feature. The charger is provided
with the compensation circuit and a 24 foot long temperature probe. The natural voltage of the battery
changes as a function of temperature change. As the Ultracap/ battery temperature rises, the effective voltage
of the Ultracap/battery decreases. Without Temperature Compensation, the Ultra Series charger will always
produce constant output voltage. As the Ultracap/battery temperature increases, this constant voltage will
then induce a higher output current from the charger. This higher current can result in overcharging the
Ultracap/battery, which in turn can result in damage or significantly shorten the life of the Ultracap/battery.
The temperature compensation considers 25°C as the nominal ambient temperature and adjusts the voltage
level based on the difference between the actual temperature and 25°C
Temperature Compensation combats this overcharging by adjusting the charger’s output voltage based on the
temperature sensed by the temperature probe. In order to increase the accuracy of the temperature
compensation the external probe can be used to measure the temperature of the Ultracap/battery.
Please see the image below for connecting temperature cable.
.
Figure 6 – Temperature Compensation Connection
emperature Probe
Connect to Negative terminal on Ultracap/Battery
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5. Operation
5.1. Front Display Panel :
(A) LCD Panel: Displays the status and output parameters of the system.
In normal operation the parameters displayed are as follows:
● Charger Output Voltage
● Charger Output Current
● Mode of Operation
➢ Float
➢ Equalize
➢ Ultracap
In case of any fault occurred, Fault message will scroll on the display.
It also allows viewing and changing the charger configuration through settings menu.
Button Switches: The unit is equipped with 6 control switches. See information below for details on the
function of each switch:
(B) Float/EQ: Allows the user to select the mode among Float mode or Equalize mode. If charger is
operating in Float mode then after pressing this switch, charger changes the mode of operation to Equalize
mode and vice versa.
Figure 7 – Front Display Panel
Note:
charger will always remain in Float mode. This switch is disabled in ULTRACAP mode.
(C) UP: Used to navigate the display parameters in an upward direction and increase the parameter value.
Switching among these modes can only happen when the charger is in battery mode. In ULTRACAP mode,
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(D) Lamp Test/ Batt. Test:
Lamp test: The Lamp test is triggered when the [Lamp Test/Batt. Test] switch is pressed
momentarily. During the test, all LED indications blink 10 times. Also, the LCD test is performed.
Battery Test: The Battery test is initialized when the [Lamp Test/Batt. Test] switch is pressed and
held for 10 seconds. System will provide a feedback through LCD panel by displaying ‘PERFORMING
BATTERY TEST’. If the battery is weak or if it is not connected to the system, ‘BATTERY FAILED’
message is displayed. To clear this message press EXIT (
If the battery is in good condition, the ‘BATTERY OK’ message appears momentarily. Then the unit
resumes normal operation.
(E) MENU/ENTER: This switch is used to set the parameter. It is also used to enter into the charger
configuration and into the submenus to select the parameters.
(F) DOWN: Used to navigate the display parameters in downward direction and decrease the parameter
value.
(G) EXIT/ RESET :
EXIT:
RESET: Unit RESET will be initialized when the
in calibration mode or in alarm state).
LEDs: There are four LEDs provided to show the status of the charger.
(H) AC ON (Green LED): LED will illuminate when the AC Mains connected to the system is in
(I) FLOAT (Green LED): LED will illuminate in Float mode.
(J) EQ (Yellow LED): LED will illuminate in Equalize mode.
(K) FAULT (Red LED): LED will illuminate when the system goes into any fault condition.
performs the back operation from any menu of the system.
button is pressed during normal operation (not
required range.
).
5.2 Initial Setup
Once all AC, DC and alarm connections have been made, apply AC power by closing the upstream AC
breaker. The unit will automatically power up. At the initial startup the ULTRA SERIES CHARGER will run at
the default settings (26 Volt Output for 24V units and 13 Volt output for 12V units; current Limit is set to
105%). In order to change these settings simply press the MENU/ENTER button to enter configuration
mode. Refer to the configuration menu flowchart on the next page (section 5.3) for details on the settings
menu structure and available parameters.
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5.3 User Menu: Symbols: # Default Value
Press MENU/ENTER button to advance to the right and EXIT (
UP/DOWN buttons to navigate between settings and settings values.
) button to navigate to the left. Use
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6. Troubleshooting
FAULT Indications on LCD CORRECTIVE ACTION
1. Check the battery connection polarity. If it not connected
Battery Reverse
High DC Voltage
AC Mains Fail
correctly, disconnect AC and connect the battery according to
right polarity.
1. Check the unit configuration for mode of operation, battery type
and cell selection.
2. Verify that the correct battery/Ultracap is connected to the unit.
1. Check if the Input AC mains is in the required range.
2. Check connections of the AC mains. Verify that the wires to AC
terminals are properly connected.
3. Check that the AC fuse is not blown. If the fuse is blown, change
the AC fuse with the same type and rating as given with the
product.
Cranking OFF
Over Temperature
Fan Failed
Temp. Probe Off
Comm. Fail
1. Wait for 2 minutes (The charger is in Self protect mode). It will
start automatically after 2 min.
1. Check that the unit ventilation is not obstructed. (e.g. – nothing
resting on top of the unit)
2. Wait for the charger temperature to be within the rating (The
charger has built-in over temperature protection). It will start
automatically when the temperature reaches within the safe
level.
1. Check if the fan is disconnected or blocked, otherwise fan is non
operational.
1. Check if the temperature probe is disconnected or cut.
2. This message will appear if the temperature at contact point is
sensed outside the range of -50°C to +150°C.
1. This message signifies the error in charger’s internal
communication. If this message appears on the display, please
consult La Marche technical support team.
Note: If any of the above mentioned or any other fault condition continue to occur, please contact
La Marche technical support at 847-299-1188.
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7. Technical Specifications
AC input Voltage and frequency Auto ranging 105-264 VAC, 45-65 Hz
Rated Current 2.6A @120VAC, 1.4A @240VAC (for 24V 10A output mode)
Input protection AC Fuse (250V, 5A Glass type)
Inrush limiting Inrush current limited NTC
Efficiency Exceeds CEC-400-2012-019-CM requirements
Power factor 0.9
Input Terminals Terminal blocks (Push-In Springable type); AWG 24 - AWG 12
Charger output Nominal voltage rating 24 volt nominal or field selectable 12/24-volt
Voltage adjustment According to selected number of cells/ Battery type and
Volt/cell.
Current 10A at 24V and 20A at 12V
Charging characteristic ULTRACAP Mode
Battery Mode
Line and load
regulation
Output ripple <100mV rms
Temperature
compensation
Output protection Electronic current limit, Transient protection,
Output Terminals Terminal blocks (Lockable type); AWG 24 – AWG 10
Status
indication
Display and
Alarms
Environmental Operating temperature -40°C to 65°C (-40°F to 149°F)
Physical Ingress Protection IP-20; NEMA-1
LED status indicator AC ON (Green LED), Float (Green LED), Equalize (Yellow LED),
Display LCD Display (16x2)
LCD Dot Matrix Display Displays volts, amps, Mode of operation and Status messages
Relay Alarm contacts Charger Fail, AC Fail, Low DC Voltage, High DC Voltage,
Relay Alarm contact
ratings
Alarm Terminals Spring Cage; AWG 24 - AWG 16
Storage temperature -40°C to 85°C (-40°F to 185°F)
Over temperature
protection
Humidity 0% to 95% non-condensing
Dimensions 7.9 x 4.1 x 10.7 in (W x D x H)
Weight 6.4 lbs (2.9 Kgs)
±0.5%
Enable/ Disable, Remote temperature sensing through probe.
DC fuse (32V, 20A Blade Fuse- Plug-In type)
Fault (Red LED)
Summary
Rated 2A @ 30 VDC, 0.5A @ 125VAC
Single form C dry type
Derates over 50C up to 70C
Above 70C, switches off.
801 x 105 x 273 mm (W x D x H)
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Document Control and Revision History
Part Number: 134372
Instruction Number: P25-USC-1
Issue ECN: 21203-1
21367 / 02-17 21341 / 01-17 21203-1 / 08-16 21203 / 07-16
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