Transcript
092-2014 LUDOCHARGER 2
INSTALLATION GUIDE AND MANUAL
LUDO CHARGER 2 12V Automatic Battery Charger For 2 12V Battery Systems
5 YEAR WARRANTY Designed and Manufactured in the UK by LUDO McGURK TRANSPORT EQUIPMENT LTD WILMSLOW - U.K.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
[email protected]
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092-2014 LUDOCHARGER 2
1.INTRODUCTION This manual describes the installation and operation of the 092-2014-12 Ludocharger 2 Battery Charger. The Ludocharger has been purposely designed for charging batteries in specialist vehicles. Its versatility means that it is also suitable for use as a bench charger or a maintenance charger for standby equipment. The Ludocharger 2 is of rugged construction and is built to withstand the shock and vibration encountered in vehicle-mounted equipment. The charger uses components that meet international safety requirements and is ideal for worldwide applications. All units are capable of operating on 110V AC or 230V AC. This is manually selectable via a switch on the front of the unit. An option is available which allows the charger to automatically switch between a 110V and a 230V power source. The unit has been designed for the charging of all types of Lead-Acid batteries, but must not be used for charging other rechargeable battery types (Nickel Cadmium, Lithium Ion etc.). The Ludocharger 2 has two individually controlled outputs which enables it to charge two different batteries simultaneously. This makes it ideal for use with vehicles which have two independent battery systems, and gives it great advantages over other multi-output chargers that have simple diode isolated outputs. The charging algorithm for each output can be individually tailored to the type of battery being charged. This means that the charger is capable of charging a standard cranking battery at the same time as a gel battery for example. Many of the charger settings (battery float voltages etc.) are installer programmable via the optional CANPower Programming Interface Module and the free CANPower programmer software. This means that anybody can tailor the charger to their individual charging requirements. The default settings of the charger are optimised for charging flooded cranking batteries.
2.MOUNTING The Ludocharger 2 should ideally be mounted as close to the batteries as possible, to minimise the battery cable length. The unit should ideally be mounted against a flat metal surface for optimum cooling. Should no such location exist in the vehicle then any reasonably flat surface can be used. It should be mounted using four M6 bolts or screws using the holes provided. It may be mounted in any orientation. The outline drawing in section 6 can be used to drill the mounting holes. The location should be chosen so that the Ludocharger 2 will not be exposed to dirt, moisture or excessive heat. Take care not to install the charger in a location where the cooling fan (on top) or air vent (at the rear) will be obstructed. It is also advisable to mount the charger in a location where the indicator LEDs can be easily seen, and the green CANPower ports are accessible for diagnostic and programming purposes.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
[email protected]
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3.ELECTRICAL CONNECTIONS 3.1 Mains Power Connection Warning: The mains connection to this battery charger involves working with wiring at dangerous voltages. This wiring must be done correctly and in accordance with the wiring regulations. If you are not qualified to do this work or are unsure what you are doing then do not do it. Either contact us for advice or consult a qualified electrician. Mains electrical installations in vehicles are now covered by the IEE wiring regulations. (Section 717, Mobile or transportable units). This means that the battery charger must be installed in accordance with these regulations. The mains installation must also be performed by a competent person. The charger is supplied with a 2M bare ended mains cable, as in most cases it will be permanently wired into a mains power supply. The charger can be supplied fitted with a suitable mains power connector at special request. If a longer mains cable is required then this can also be specified at the time of ordering. 3.1.1 Input Voltage Selection Warning: Do not connect the charger to the wrong voltage! Connecting the charger to a 110V supply when it is set to 230V will simply result in the charger not functioning. Connecting the charger to a 230V supply when it is set to 110V will result in damage to the charger. All units are supplied set to 230V, as in most cases this is the voltage they are used on. However there are many 110V installations so the voltage change switch is provided to allow this. This is located on the front of the charger, to the left of the green CANPower connectors. In order to change the operating voltage, using a small screwdriver, slide the switch so that it reads the required voltage setting.
A label is supplied to cover over the switch so that it does not get changed once installed.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
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3.1.2 Mains power connection If the charger is to be used for a portable application, then the mains power cable will need to be fitted with a suitable mains connector. In a vehicle mounted installation, the mains power for the charger will usually be supplied by an externally mounted connector such as an Auto Eject. The power may also come from another source such as a vehicle mounted generator. Whatever the source of mains power, an electric shock protection device must be installed inside the vehicle. This is a requirement of the IEE wiring regulations. This device must be placed between the mains power source and the battery charger. This can be either an RCD or an RCBO. A double pole RCBO is recommended as includes protection against both electric shock and overcurrent faults. A double pole device must be used in a 110V installation, due to there being two live conductors. We supply a wide range of RCBOs which are suitable for this application and are supplied with a bulkhead mounting case for convenient installation.
3.1.3 Powering up the unit Once the mains installation is complete, it is good practice to power up the charger without it being connected to a battery to verify the correct operation of the unit. Once powered, the power/status LED should be constant green. The battery 1 status and battery 2 status LEDs should be slowly flashing red, indicating that there are no batteries connected. The battery 1 current and battery 2 current LEDs should both be off. 3.2 Battery Connection Warning: Take care when handling Lead-Acid batteries. Lead-Acid batteries which are in a poor state may leak Suplhuric acid which can cause burns if it comes into contact with your skin or eyes. Lead-Acid batteries may also vent Hydrogen during charging which is an explosive gas. Always ensure that batteries which are being charged have adequate ventilation, and are kept away from sources of ignition. When connecting a battery charger to a battery ensure that that battery charger is switched off, otherwise sparks may ignite any explosive gases present. The battery cable connection is essentially simple but it is critical that it is done correctly as it will have a large effect on the performance of the charger.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
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Below is a diagram showing a typical installation of the LudoCharger 2 in a 2 battery system:
3.2.1 Choice of Battery Cables The choice of cable for the output of the battery charger is very important. We recommend using standard automotive grade flexible multi-stranded cable. It is good practice to use red cable for the positive connection and black cable for the negative connection. A common mistake many people make is to choose a cable by its current rating. Whilst it may seem logical to do this in this case it would be a mistake. There are many reasons for this but they are outside the scope of this instruction manual. The main reason is that the charger uses the cable to sense the condition of the batteries, and with a thicker cable the charger is more able to do this. The maximum cable size that will fit into the output terminals is 16mm2 (126/0.4 Strand) For this 12V 30A charger a minimum cable size (CSA) of 10mm2 (80/0.4 Strand) must be used. For optimum charging performance a cable of 16mm2 (126/0.4 Strand) should be used. A good rule of thumb is to use the thickest cable that you can fit into the installation, and to keep the cable as short as possible. If the installation is planned so that the charger is as close to the batteries as possible then this will help. Each cable should be a single piece of cable with no joints which runs directly from the charger to the batteries. A suitable cable of the required length and correct terminations can be supplied with the charger if specified at the time of ordering. The battery cables will become warm in normal charger operation. Avoid bundling and sleeving these cables if possible as this will inhibit their ability to cool. If it is necessary to sleeve the cables then sleeve them individually, and if possible increase the cable size to compensate.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
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3.2.2 Fuses Where fuses are required for compliance reasons, or in permanently wired or unattended installations, then a suitable fuse must be placed at the battery end of the charger cable. A common mistake is to use a fuse that is too small, and nuisance (non-fault) fuse blowing may be experienced. For this 30A charger the fuse should be rated between 40A to 50A. Suitable fuse types are either Maxi-Blade fuses or Midi fuses. A good rule of thumb is to choose a fuse rating that is 50% greater than the maximum charger output. The fuse rating must always be less than the maximum current rating of the cable used in the installation.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
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3.2.3 Battery Cable Charger Connection The Ludocharger 2 uses high quality tension clamp terminals for the output cables. These have many advantages over traditional screw terminals such as an inability to be overtightened and an excellent resistance to vibration. The following guide has been provided for people who are unfamiliar with their operation: 1. Opening the terminal. Insert a 4mm-6mm flat bladed screwdriver into the slot above the terminal you want to open. As you push the screwdriver in you should see the terminal begin to open. Continue to push and the terminal should open fully.
2. Cut the cable so that the end of the cable is square, then strip off 12mm of the cable insulation. Insert the cable into the open terminal. This should be easy to do, if it is not then either the terminal is not open fully or some cable strands have splayed out and have not entered the connector. If this happens, remove the cable, straighten the strands and reinsert it until it is correct. 3. With the cable inserted, remove the screwdriver. The cable will now be firmly held in the terminal.
4. Repeat the process for the other cables.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
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3.2.4 Battery Connection The charging cables should be run from the charger directly to the batteries. It is important that both the positive and negative cables are run from the charger to the battery posts, as this will allow the charger to work most effectively. • • •
Do Not use the vehicle chassis as a ground return for the charger Do Not connect either cable to a busbar or common grounding point, connect only to the battery terminals. Do Not connect anything except fuses between the charger and the batteries. This includes manual isolator switches, relays, automatic battery isolators, split charging diodes, current shunts etc.
The battery cables should be terminated using copper tube terminals or similar. For batteries with bolt type connections then the cables can be connected directly to the battery. For batteries with post type terminals then a suitable battery post terminal will be required to connect the cable to the battery. 3.3 CANbus Terminator The charger is supplied with a CANbus termination connector. This should be installed in one of the green CAN ports on the front of the charger. This connector needs to be present when the installer connects the CANPower Programming Interface Module to the charger for programming and diagnostic purposes. This is explained further in section 5.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
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4. OPERATION 4.1 Charger Indicator LEDs The following is a quick reference explaining the different states of the 5 indicator LEDs on the front of the unit. Their function is fully explained in the later sections: •
Power / status LED: o Off: Charger is off o Flashing green: Power on self-test. o Constant green: Charging o Flashing red: Charger protection (thermal shutdown etc.).
•
Battery 1 status LED: o Flashing green: Battery 1 sense. o Constant red: Battery 1 in bulk charge or absorption charge mode. o Constant green: Battery 1 in float charge mode. o Slow flashing red (1 second flash cycle): No battery detected. o Fast flashing red (0.5 second flash cycle): Battery 1 fault condition.
•
Battery 1 current LED: o Constant blue: Battery 1 charging. Battery 1 output is being current limited. o Flashing blue (variable pulse width, see below): Battery 1 charging. Battery 1 output is supplying current below the current limit. o Constant off: Battery 1 charged. Battery 1 output is giving very little or no current.
•
Battery 2 status LED: o Flashing green: Battery 2 sense. o Constant red: Battery 2 in bulk charge or absorption charge mode. o Constant green: Battery 2 in float charge mode. o Slow flashing red (1 second flash cycle): No battery detected. o Fast flashing red (0.5 second flash cycle): Battery 2 fault condition.
•
Battery 2 current LED: o Constant blue: Battery 2 charging. Battery 2 output is being current limited. o Flashing blue (variable pulse width, see below): Battery 2 charging. Battery 2 output is supplying current below the current limit. o Constant off: Battery 2 charged. Battery 2 output is giving very little or no current.
The battery 1 and battery 2 current LED pulse width corresponds to the percentage of the maximum output current that the charger is giving. I.E. if the LED duty cycle is 50% then the output current is 50% of the maximum. The maximum output current of a 12V charger is 30A, so the output current would be 15A. 4.2 Charger Operating States The Ludocharger 2 is an intelligent device which has several operating states that it goes through in the process of charging batteries. They are as follows:
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
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4.2.1 Power On Self Test When the charger is first switched on, it performs a set of internal tests on itself to make sure that it is operating properly before it starts to charge batteries. During this process the power/status LED flashes green. This process normally takes no longer than 2 seconds, and once complete it proceeds to the charging state. 4.2.2 Charging In this state the battery charger charges the batteries using the charging algorithm that has been selected for each output. In this state the power/status LED will be constantly green. The charger will continue to monitor itself for problems and go to the fault state if it finds any. 4.2.3 Charger Protection The charger will be in this state if it has detected a fault condition which may cause damage to the charger. A good example of this will be if the charger has overheated due to inadequate ventilation. In this state the power/status LED will flash red, and the charger will not give any output. The charger will continue to check itself to see if the fault condition has been corrected. An example of this would be if the charger has entered the fault condition due to overheating, and has then cooled down as it has not been giving any output. It the fault has cleared then the charger will return to the charging state to continue battery charging. 4.3 Charging Algorithms Once the charger has entered the charging state, it will proceed through a series of steps called an algorithm in order to completely charge the battery. Before it does this the charger analyses the batteries to check that it is safe and appropriate to commence with the charging algorithm. During this process the respective battery status LED will flash green. This process should last no longer than 2 seconds. If everything is ok, then the charger will proceed with the charging algorithm. If a problem is detected with the battery such as excessive voltage, then the output will go into the battery error state. The battery status LED will fast flash red (0.5 second flash cycle). An example of this would be if a 12V charger was connected to a 24V battery, and vice versa. If the charger cannot detect a battery connected to the output, then the battery status LED will slow flash red (1 second flash cycle). If the battery voltage is below 2V (the minimum charging threshold) when the charger is switched on then this will read as no battery connected. This is a safety feature that prevents the charger giving output when the output is shorted. 4.3.1 Two Stage Charging Algorithm (Float Charging) The two stage charging algorithm is essentially a very simple charging algorithm, which is the most appropriate one for charging batteries which have parasitic loads attached to them. A parasitic load is any device which is permanently connected to the battery and is always drawing current from the battery. In vehicle mounted applications such as ambulances and fire appliances this is usually the case, and as such this is the default charging algorithm for the LudoCharger 2. A two stage charging
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
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algorithm will take longer to charge batteries than a three stage algorithm, but there is no risk of battery overcharging, and batteries will have a much longer life. The first stage is called constant current mode or bulk mode. The battery charger supplies current to the battery up to the maximum current limit of the charger (30A for a 12V charger). In this stage the battery status LED will be constantly red, and the battery current LED will be constant blue. It is in this stage that most of the battery’s charge is replaced (hence bulk mode). During this stage the charger constantly monitors the battery voltage. Once the battery voltage reaches the float voltage threshold, which is 13.25V by default, the charger will switch to the second charging stage. The second stage is called constant voltage mode or float mode. The battery charger supplies current to the battery at a level which maintains the battery voltage at the float voltage threshold. In this stage the Battery status LED will be constantly green, and the battery current LED will flash blue. As the battery continues to charge the amount of current supplied will decrease. If at any time the output current reaches the current limit, then the charger will go back into constant current mode. When the battery is completely charged, the charger will continue to keep the battery voltage at 13.25V for the rest of the time that the charger is switched on, to prevent self discharge. This graph shows a typical two stage charging cycle:
In both stages the charger continuously monitors the battery for fault conditions. If one is detected, it will cease giving output and enter the battery error state. 4.3.2 Three Stage Charging Algorithm (Fast Charging) The three stage charging algorithm is very similar to two stage charging, but includes a third intermediate stage called absorption mode. Three stage charging is the fastest way of charging a lead-acid battery, and is most suited to maintenance charging applications. It can only be used where there is little or no load on the battery while it is being charged. In a specialist vehicle installation it is highly likely that equipment will be drawing current from the battery constantly, and as such makes three stage charging unsuitable. Great care must be taken when installing a three stage charger into a vehicle to make sure that batteries do not get damaged as a result.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
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As with two stage charging, the first stage is called constant current mode or bulk mode. The battery charger supplies current to the battery up to the maximum current limit of the charger (30A for a 12V charger). In this stage the battery status LED will be constantly red, and the battery current LED will be constant blue. It is in this stage that most of the battery’s charge is replaced (hence bulk mode). During this stage the charger constantly monitors the battery voltage. Once the battery voltage reaches the absorption voltage threshold, which is 14V by default, the charger will switch to the second charging stage. The second stage is a constant voltage mode called Absorption mode. The battery charger supplies current to the battery at a level which maintains the battery voltage at the absorption voltage threshold, which is 14V by default. In this stage the Battery status LED will be constantly red, and the battery current LED will flash blue. As the battery continues to charge the amount of current supplied will decrease. If at any time the output current reaches the current limit, then the charger will go back into constant current mode. Once the amount of current going to the battery falls below the Absorption current threshold (4A by default), the charger will switch to the third charging stage. The third charging stage is another constant voltage mode called float mode. The battery charger supplies current to the battery at a level which maintains the battery voltage at the float voltage threshold, which is 13.25V by default. In this stage the Battery status LED will be constantly green, and the battery current LED will flash blue. The battery is almost completely charged at this stage. The charger will stay in this stage for the rest of the time the charger is on, to prevent self discharge. This graph shows a typical three stage charging cycle:
In all stages the charger continuously monitors the battery for fault conditions. If one is detected, it will cease giving output and enter the battery error state.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
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5. PROGRAMMING AND DIAGNOSTICS Disclaimer: Ludo McGurk Transport Equipment Ltd. Will not accept responsibility for damage to vehicle batteries that has been caused by inappropriate voltage/current settings which have been customer programmed. Changing these settings must be done very carefully. Make sure that the settings that you choose are suitable for the batteries that the charger is connected to. If you are unsure then contact us for advice. With the CANPower Programming Interface Module you can use a Windows PC loaded with the CANPower Programmer software to alter some of the default settings of the Ludocharger 2. You may wish to alter some of the settings if: • • • •
You want to charge a different type of lead acid battery such as an AGM battery on one of the outputs, and you want to change the float voltage setting of that output. You want to charge a small battery on one of the outputs, and need to lower the maximum charging current to that battery. You may wish to change the charging algorithm of an output from 2-Stage to 3-Stage. You may wish to change the absorption current threshold to allow for a small parasitic load.
It is also a very useful tool to have should there be any problems with battery charging on a vehicle. The programming window shows useful information such as the battery voltage and output current.
If you do not have a CANPower Programming Interface Module then we can supply the chargers pre-programmed with settings that you specify at the time of ordering.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
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6. SPECIFICATION AND OUTLINE DRAWING Weight of all models: 5Kg Model Specifications: Part No. 092-2014-12
Battery Voltage 12V DC
Output Current 30A DC
Input Voltage 110VAC or 230VAC 50/60Hz
Input Current 6.2A @ 110VAC or 3.4A @ 230VAC
Outline Drawing:
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
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7. TROUBLESHOOTING If you are having any of the following problems then use this troubleshooting guide to try and solve the problem. If the problem you are having is not described below or you still cannot find the cause, then contact us for help. Symptom Charger not functioning. No output and power/status LED is off
Possible Cause No mains power to the charger
Charger fuse has blown. Charger possibly connected to wrong voltage. Charger functioning but no output, power/status LED is flashing red.
Charger has overheated and shut down.
Solution Check the power supply to the vehicle. Check that the RCBO has not tripped or been switched off. Check all the mains power connections. Use a multimeter to check continuity between the Live and Neutral terminals. If no continuity, fuse has blown. Return charger for repair. Check ventilation to the unit. Make sure that all vents are clear and that the mounting location is adequately ventilated. Check that the fan is running, it should be running even if the unit has shut down due to overheating. Contact us for help.
Charger has detected a different internal fault and shut down. Charger functioning Charger cannot detect a Check all battery cable connections. but no output, battery connected to the Check continuity between the battery power/status LED is output terminals and the charger with a constant green. multimeter. Battery X status LED is Battery voltage is below the Check the condition of the battery. A slow flashing red (1s minimum charging threshold. battery with a voltage this low will probably flash cycle) need replacing. Charger functioning but no output, power/status LED is constant green. Battery X status LED is fast flashing red (0.5s flash cycle)
The output has been connected to the wrong battery voltage.
Check that the output has been connected to the correct type of battery (12V output to a 12V battery).
A fault has been detected with Check the condition of the battery. the battery during charging.
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TEL: +44 1625 527 673
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WARRANTY All products of Ludo McGurk Transport Equipment Ltd. are warranted to be free of defects of material or workmanship. Liability is limited to repairing or replacing at our factory, without charge, any material or defects which become apparent in normal use during the warranty period as shown on the front of this manual. The warranty period runs from the date the equipment was originally shipped from Ludo McGurk Transport Equipment Ltd to you. Equipment is to be returned; shipping charges prepaid and will be returned after repair, return shipping charges paid. Ludo McGurk Transport Equipment Ltd shall have no liability for damages of any kind to associated equipment arising from the installation and /or use of any Ludo McGurk Transport Equipment Ltd products. The purchaser, by the acceptance of the equipment, assumes all liability for any damages, which may result from its installation, use or misuse, by the purchaser, his/her or its employees or others.
LUDO McGURK SVE UNIT 3 CROSSFIELD ROAD, HANDFORTH, CHESHIRE, SK9 3LN.
TEL: +44 1625 527 673
FAX: +44 1625 549 929
WEB: www.ludomcgurk.co.uk
EMAIL:
[email protected]
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