Models - Lester Electrical
Contents
1. 39251D Summit Series 20 of 20 User s Manual2. Unpack the charger and examine it for shipping damage In the event that shipping damage is found report it as a claim with the freight company Do not operate the charger with a damaged AC or DC cable or connector Do not operate the charger if it has received a sharp blow was dropped or was otherwise damaged in any way Contact your dealer Proper installation is important to achieve optimum performance and life from the charger and batteries Allow as much free air space around the charger as possible Please refer to the Specifications section for specific storage and operating environmental specifications The charger was factory configured for mounting on board a battery powered vehicle machine or off board use in a shelf or portable application Contact your dealer if you desire to use the charger in a non factory configured manner The most favorable orientations of the charger are shown in Figure 2 1 For on board use the most favorable way to mount the charger is with the charger base bolted to a metal plate 0 1 inch minimum This provides both a strong structural mounting and good thermal conductive cooling examples are shown in Figure 2 1 Views A and B A poor thermal conductive mounting material such as plastic or wood would be less favorable for cooling The charger dimensions and mounting slot locations are shown in Figure 2 2 For off board use optional handles are available for ease in carrying Summit Series 7 o
3. SHOCK Awarnine LEAD ACID BATTERIES GENERATE EXPLOSIVE GASES TO PREVENT ARCING OR BURNING NEAR BATTERIES DO NOT DISCONNECT DC CHARGING CORD FROM BATTERIES Summit Series 5 of 20 User s Manual 14 15 16 17 18 19 20 WHEN THE CHARGER IS OPERATING KEEP SPARKS FLAME AND SMOKING MATERIALS AWAY FROM BATTERIES A WARNING ALWAYS SHIELD EYES WHEN WORKING NEAR BATTERIES DO NOT PUT WRENCHES OR OTHER METAL OBJECTS ACROSS BATTERY TERMINAL OR BATTERY TOP ARCING OR EXPLOSION OF THE BATTERY CAN RESULT A WARNING BATTERIES PRODUCE HYDROGEN GAS WHICH CAN EXPLODE IF IGNITED NEVER SMOKE USE AN OPEN FLAME OR CREATE SPARKS NEAR THE BATTERY VENTILATE THE AREA WHEN THE BATTERY IS CHARGING IN AN ENCLOSED PLACE N WARNING LEAD ACID BATTERIES CONTAIN SULFURIC ACID WHICH MAY CAUSE BURNS DO NOT GET ACID IN EYES ON SKIN OR CLOTHING IF CONTACT WITH THE EYES OCCURS FLUSH IMMEDIATELY WITH CLEAN WATER FOR 15 MINUTES AND OBTAIN MEDICAL ATTENTION Awarnine ONLY A QUALIFIED SERVICE TECHNICIAN SHOULD PROGRAM OR SERVICE THIS EQUIPMENT Acaution DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW BEEN DROPPED OR OTHERWISE DAMAGED HAVE A QUALIFIED SERVICE TECHNICIAN EXAMINE AND REPAIR AS NEEDED Awarnine DO NOT DISASSEMBLE THE CHARGER HAVE THE CHARGER EXAMINED BY A QUALIFIED SERVICE TECHNICIAN INCORRECT RE ASSEMBLY OF THE CHARGER MAY RESULT IN AN EXPLOSION ELECTRIC SHOCK OR FIRE Acaution MAKE SURE
4. THE BATTERY SYSTEM HAS THE PROPERLY RATED VOLTAGE AMP HOURS AND TYPE WET AGM GEL ETC FOR THIS CHARGING SYSTEM SAVE THESE INSTRUCTIONS Summit Series 6 of 20 User s Manual 1 INTRODUCTION This switch mode high frequency industrial battery charger features advanced charge and termination algorithms designed to optimize both daily battery capacity and overall battery life The charger is convection cooled with no moving parts sealed and designed to provide maximum reliability The universal AC input enables the charger to be used with a wide range of AC voltages and frequencies and the charger includes high efficiency and power factor The charger was factory configured with a battery profile intended for use with batteries of the same type voltage and number of cells as is listed on the ratings label see the Charger Ratings Label section for additional details The charger was also factory configured for on board or off board use Contact your dealer if you require a different configuration 2 RECEIVING AND INSTALLING THE CHARGER A WARNING DO NOT INSTALL THE CHARGER ON OR NEAR FLAMMABLE MATERIALS POSITION THE CHARGER ON A FOUNDATION OF STONE BRICK CONCRETE OR GROUNDED METAL A WARNING CHARGERS CAN IGNITE FLAMMABLE MATERIALS AND VAPORS DO NOT USE NEAR FUELS GRAIN DUST SOLVENTS THINNERS OR OTHER FLAMMABLES A WARNING REPLACE WORN DAMAGED OR CUT ELECTRICAL CORDS AND PLUGS IMMEDIATELY
5. 1 Gel standard Wet standard 6A finish W4 Wet standard 8A finish 28000 48V 19 5A W6 Wet standard 11A finish A1 AGM standard G1 Gel standard Figure 3 1 Standard Battery Profile Codes and Their Corresponding Battery Profiles Continued Battery manufacturers frequently use the same battery cases for different battery types Wet flooded batteries have removable cell caps Water electrolyzed by discharging and charging the battery is replaced through these openings Sealed batteries are generally distinguished by non removable cell caps The physical appearance of the battery case is frequently the same as a wet battery though the cell caps are generally not removable Refer to the battery manufacturer s information panel on the battery case to determine the type battery you have If the information panel is missing or not legible do not use the battery 4 OFF BOARD SHELF VERSUS ON BOARD BUILT IN CHARGERS 4 1 Off Board Chargers Off board chargers are designed to be used in shelf or portable applications If the AC input plug is connected to AC power a new charge cycle automatically starts when the DC output is connected to a battery pack of the proper voltage Disconnecting and reconnecting AC power while the DC output remains connected to a battery pack WILL NOT automatically start a new charge cycle Disconnecting the DC output from the battery pack IS REQUIRED to automatically start a new charge cycle 4 2 O
6. 2 On Board Charger Operation If the charger was factory configured for on board use follow these operating instructions 1 Ensure that the vehicle equipment that the charger is mounted on is turned off 2 With the charger AC power cord disconnected from the AC outlet connect the charger DC output connector plug to the battery connector receptacle most likely already connected or hard wired 3 Connect the charger AC power cord to an appropriate AC outlet The charger will start automatically which is indicated by the Charge Status yellow LED beginning to blink slowly 4 charger must be disconnected from the battery while a charge cycle is in progress disconnect the AC power cord from the AC outlet Do not disconnect the charger DC output connector plug from the battery while a charge cycle is in progress 5 The charge cycle 8096 point is indicated by the Charge Status yellow LED beginning to blink quickly 6 The Finish charge cycle phase is indicated by the solid illumination of the Charge Status yellow LED Not all charge profiles include a Finish phase Summit Series 14 of 20 User s Manual 7 An extended Balance Equalize charge cycle phase is indicated by the Charge Complete green LED beginning to blink quickly Not all charge profiles include a Balance Equalize phase 8 The charger automatically terminates the charge cycle when a battery reaches full charge which is indicated by 1 the solid illumination of
7. 30231 SUMMIT Oo SWITCH MODE INDUSTRIAL BATTERY CHARGER USER S MANUAL Important Safety Installation Operation and Maintenance Instructions www LesterElectrical com Summit Series 2 of 20 User s Manual CHARGER RATINGS LABEL The ratings label is located on the back of the charger The label provides the model MODEL part number PART NO serial number SERIAL NO AC input ratings INPUT and DC output ratings OUTPUT CELLS and AH of the charger The amp hour AH rating indicates the full range of battery capacities that are recommended for use with this charger Different battery profiles may be required to optimize the charging of specific battery capacities within this range The BATTERY field indicates the factory configured battery profile An example charger ratings label is provided below ERIAL NO 10130316 E NO MODEL OUTPUT 48VDC 13A 97790 INPUT 100 230VAC 50 60Hz 1PH lt 8A BATTERY WET PDVDT 24CELLS 140 225AH Please fill in the blank label that is provided below with the information from the ratings label on your charger for future reference ERIAL NO PART NO OUTPUT VDC INPUT BATTERY Document any configuration or settings changes that are made by marking the ratings label on your charger or on an additional label or tag attached to your charger SAVE THIS MANUAL Keep it in a location where it is available to anyone who may oper
8. An extended charge cycle Fast Blink is occurring because a trigger condition has been met cycle count etc Not all charge profiles include a Balance Equalize phase Charge cycle complete Post Charge phase Slow Blink constant voltage float etc Not all charge profiles include a Post Charge phase Solid On Charge cycle complete Figure 11 1 Charger LED States Non Fault Summit Series 15 of 20 User s Manual 12 FAULTS 0 Off 1 On Solid N A Not applicable LED state does not matter Red LED DC DISCONNECT DC disconnect Slow Blink detected via the third pin but DC battery voltage is still present at the charger Slow Blink Slow Blink output Third pin DC disconnect sensing is an optional feature available with supported DC plug receptacle systems to Slow Blink Slow Blink Slow Blink Slow Blink 1 minimize charger output inhibit time when a DC disconnect occurs during charging OVER TEMP Maximum temperature 1 was met Charge cycle will restart when the temperature decreases LOW DC DC battery voltage is too low to start charging 10V NO AC AC power was lost during charging Charge cycle will restart when AC power returns HARDWARE FAULT Contact Lester Slow Blink 4 Electrical HARDWARE FAULT Contact Lester Electrical Slow Blink Slow Blink 1 HARDWARE FAULT Contact Lester Electrical HARDWARE FAULT Contact Lester Electrical Unit is still able to c
9. CHE Awarnine LEAD ACID BATTERIES GENERATE GASES WHICH CAN BE EXPLOSIVE TO PREVENT ARCING OR BURNING NEAR BATTERIES DO NOT DISCONNECT THE CHARGER DC OUTPUT FROM THE BATTERIES WHEN THE CHARGER IS OPERATING KEEP SPARKS FLAME AND SMOKING MATERIALS AWAY FROM BATTERIES Summit Series 13 of 20 User s Manual Awarnine ALWAYS SHIELD EYES WHEN WORKING NEAR BATTERIES DO NOT PUT WRENCHES OR OTHER METAL OBJECTS ACROSS BATTERY TERMINALS OR THE BATTERY TOP ARCING OR EXPLOSION OF THE BATTERY CAN RESULT Awarnine DO NOT DISCONNECT THE CHARGER DC OUTPUT CONNECTOR FROM THE BATTERY CONNECTOR WHILE A CHARGE CYCLE IS IN PROGRESS THE RESULTING ARCING AND BURNING OF THE CONNECTORS COULD CAUSE THE BATTERIES TO EXPLODE AVOID DAMAGE TO THE CHARGER DC CABLE AND CONNECTOR AND BATTERY CONNECTOR DISCONNECT BY GRASPING THE CHARGER CONNECTOR HANDLE OR BODY AND PULLING IT STRAIGHT OUT OF THE BATTERY CONNECTOR DO NOT PULL ON THE CHARGER CABLE DO NOT TWIST ROCK OR PULL THE CONNECTOR SIDEWAYS The instructions printed on the charger are for daily reference 10 1 Off Board Charger Operation If the charger was factory configured for off board use follow these operating instructions 1 With the charger DC output connector plug disconnected from the battery connector receptacle connect the charger AC power cord to an appropriate AC outlet if not already connected 2 Connect the charger DC output connector plug to the batter
10. E LEAD ACID MOTIVE POWER BATTERIES 12 9 1 Personal Safety Precautions E E Cn C E 13 10 CHARGER OPERATION etin area p ce RETRO epu Er ERR RE EO Eu QUERN CER aS 13 10 1 Off Board Charger Operation U U J 14 10 2 On Board Charger Operation U 14 11 LED INDICATORS 15 12 FAULTS tE nei 16 13 TROUBLESHOOTING 17 T4 SPECIFICAT ON S uuu riae te RE RE 18 Summit Series 4 of 20 User s Manual 10 11 12 13 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety and operating instructions Before using battery charger read all instructions and cautionary markings on battery charger battery and product using battery IT MEANS ALERT YOUR SAFETY IS INVOLVED IF YOU DO NOT FOLLOW THESE SAFETY INSTRUCTIONS INJURY OR PROPERTY DAMAGE CAN OCCUR LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK CAREFULLY READ AND FOLLOW THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS BEFORE INSTALLING OR OPERATING THE CHARGER INSTRUCTION
11. ERMINALS REPLACE DEFECTIVE CORDS WIRES OR CONNECTORS IMMEDIATELY 6 DC OUTPUT Awarnine LEAD ACID BATTERIES GENERATE EXPLOSIVE GAS CHARGE ONLY IN WELL VENTILATED AREAS TO PREVENT ARCING OR BURNING NEAR BATTERIES DO NOT DISCONNECT THE DC CHARGING CONNECTOR S FROM THE BATTERIES WHEN THE CHARGER IS OPERATING IF THE CHARGE CYCLE MUST BE INTERRUPTED UNPLUG THE AC POWER CORD BEFORE DISCONNECTING THE DC OUTPUT CONNECTOR S FROM THE BATTERIES KEEP SPARKS FLAME AND SMOKING MATERIALS AWAY FROM BATTERIES TO REDUCE THE RISK OF FIRE DO NOT USE THE CHARGER NEAR FLAMMABLE MATERIALS OR VAPORS Only charge batteries of the same type voltage number of cells and amp hour capacities listed on the charger ratings label The DC output cordset includes a commonly used connector plug The polarity of the charger DC connector plug must be the same as the battery connector The BLACK DC cable must be connected to the battery negative and the WHITE or RED DC cable must be connected to the battery positive The charger will not operate if the polarity is reversed 7 VEHICLE LOCKOUT CONTROL OPTIONAL The charger may be configured with an optional lockout interlock control signal to prevent vehicle equipment operation while the charger is in use If the charger was factory configured for on board use the lockout control signal will be active while AC power is applied to the charger If the charger was factory configured for off board use the lock
12. G05K5B1A1 has a primary battery profile code of A1 Figure 3 1 lists standard battery profile codes and their corresponding battery profiles If the battery profile code for your charger is not listed in Figure 3 1 please contact your dealer for information To change the active battery profile for this charger please contact your dealer If the active battery profile is changed mark the charger ratings label or add an additional label or tag CAUTION THIS CHARGER IS FOR USE ONLY WITH BATTERY SYSTEMS OF THE SAME TYPE AS THE ACTIVE BATTERY PROFILE BATTERIES IMPROPERLY MATCHED WITH THE CHARGER MAY BURST CAUSING PERSONAL INJURY AND DAMAGE TO THE BATTERIES OR CHARGER Model Rating db it ea Battery Profile W1 Wet standard 4 5A finish W2 Wet temp comp 4 5A finish 27790 27800 48V 13A W4 Wet standard 6A finish A1 AGM standard G1 Gel standard Wet standard 6A finish 28110 28120 36V 14 5A A1 AGM standard G1 Gel standard W1 Wet standard 7A finish W4 Wet standard 9A finish 27940 24V 25A W6 Wet standard 11A finish A1 AGM standard G1 Gel standard Figure 3 1 Standard Battery Profile Codes and Their Corresponding Battery Profiles Summit Series 9 of 20 User s Manual Model Rating gu Battery Profile W1 Wet standard 7A finish W4 Wet standard 9A finish 28230 36V 21A W6 Wet standard 11A finish A1 AGM standard G
13. RISK OF ELECTRIC SHOCK OR FIRE See the FAULTS section for information regarding the Fault LED 1 If the charger does turn check for one of the following conditions a b C d The charger AC power cord is not plugged into a live and or appropriate AC outlet The battery connections are incorrect battery not connected reverse polarity or short circuit The battery voltage is too high The battery voltage is too low below 10 volts If the charger turns off before a battery is fully charged and a fault condition is not indicated by the Fault LED this indicates one of the following conditions a b AC power was interrupted during the charge cycle The charger DC output connector was disconnected from the battery during the charge cycle The battery has been allowed to sulfate Charge the battery at least once every three 3 days when the equipment is lightly used Once sulfation is allowed to take place it may be partially reduced by returning temporarily to daily charging Adecrease in vehicle equipment range where the battery loses power faster indicates one of the following conditions a The electrolyte level in a wet lead acid battery was allowed to drop below the top of the battery plates If so add distilled water to just cover the top of the plates immediately upon discovery and then fill to the proper level with distilled water at the completion of the very next charge cy
14. S IMPORTANTES CONCERNANT LA SECURIT Awarnine TO REDUCE THE RISK OF FIRE INSTALL THIS BATTERY CHARGER ON A SURFACE OF NON COMBUSTIBLE MATERIAL SUCH AS BRICK CONCRETE OR METAL DANGER RISK OF ELECTRIC SHOCK DISCONNECT CHARGER FROM BATTERY AND AC POWER BEFORE SERVICING TURNING OFF THE CHARGER DOES NOT REDUCE THIS RISK DANGER RISK OF ELECTRIC SHOCK DO NOT TOUCH UNINSULATED PORTION OF AC OR DC CONNECTORS OR UNINSULATED BATTERY TERMINAL DANGER RISQUE DE CHOCKS LECTRIQUES NE PAS TOUCHER LES PARTIES NON ISOLEES DU CONNECTEUR DE SORTI OU LES BORNES NON ISOLEES DE L ACCUMULATEUR Acaution CHARGE ONLY BATTERIES OF THE SAME TYPE VOLTAGE CELL NUMBER AND AMP HOUR CAPACITIES AS SHOWN ON THE LABEL OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE BEFORE CHARGING ANY OTHER TYPE OF RECHARGEABLE BATTERY CHANGE THE CHARGER SETTINGS AS RECOMMENDED BY THAT BATTERY MANUFACTURER ATTENTION UTILISER POUR CHARGER UNIQUEMENT LES ACCUMULATEURS AU PLOMB ELECTROLYTE LIQUIDE D AUTRES TYPES D ACCUMULATEURS POURRAIENT ECLATER ET CAUSER DES DANGER TO PREVENT ELECTRICAL SHOCK DO NOT TOUCH EITHER AC OR DC UNINSULATED PARTS MAKE SURE ALL ELECTRICAL CONNECTORS ARE IN GOOD WORKING CONDITION DO NOT USE CONNECTORS THAT ARE CRACKED CORRODED OR DO NOT MAKE ADEQUATE ELECTRICAL CONTACT USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY RESULT IN A RISK OF OVERHEATING OR ELECTRIC SHOCK N WARNING HAZARD OF ELECTRIC
15. ate the charger Summit Series 3 of 20 User s Manual TABLE OF CONTENTS CHARGER RATINGS LABEL Rand a tuna ra qa E a Lua a9 ata ER aro CE E EE Ci aas 3 TABLE 5 22 044 1 12 42 4 1 4 IMPORTANT SAFETY INSTRUGTIQNS J J J 5 1 INTRODUCTION un 2222 41 aka kk ax ba aa iu sau eR ULL E a a aa ONU LL aada da UM REI ERR UN UR 7 2 RECEIVING AND INSTALLING THE 0 4 7 3 BATTERY TYPE 9 4 OFF BOARD SHELF VERSUS ON BOARD BUILT IN CHARGERS 10 4 1 OIf Board Chargers P n dice edicto nba E u Ee 10 4 2 On Board Chargers 10 5 AG INPUT eum 10 6 DG OUT PUR a ka uta a T 11 7 VEHICLE LOCKOUT CONTROL OPTIONALL 11 8 BATTERY TEMPERATURE SENSOR OPTIONALL 12 9 PROPER CARE OF DEEP CYCL
16. cle b Use of the vehicle equipment before the battery has been fully charged and the charger automatically terminates the charge cycle This shortens battery life and accelerates the onset of reduced daily range c The normal wear out pattern for the battery A charge cycle running longer than anticipated before terminating indicates one of the following conditions a An overly discharged battery b The charger output may have been reduced due to low AC input voltage high ambient temperature or obstructions to cooling airflow c The amp hour capacity of the battery is greater than the charger can fully charge in the anticipated amount of time Summit Series 17 of 20 User s Manual 14 SPECIFICATIONS AC Input Voltage range rated Voltage range operating Frequency rated Frequency operating Phase Current maximum Protection DC Output Voltage nominal Voltage maximum Voltage minimum start up Power Current rated Current maximum Battery types Protection LEDs Lockout Control Battery Temp Sensor Remote LEDs Mechanical Dimensions amp mounting pattern Weight approximate Cooling AC connector Mounting Handle Environmental Enclosure rating Operating temperature Storage temperature 100 230 Vac 90 264 Vac lt 100 Vac reduced power 50 60 Hz 45 65 Hz Single phase 27790 27800 28110 28120 27940 8A 28000 28230 12A Current limit surge transient
17. diately flush your eye with running cold water for at least 10 minutes and get medical attention immediately NEVER smoke or allow a spark or flame to be in the vicinity of a battery Be extra cautious to reduce the risk of dropping a metal tool onto a battery It could spark or short circuit the battery or other electrical components that could cause an explosion 7 Remove personal metal items such as rings bracelets necklaces and watches when working with a battery A battery can produce a short circuit current that is high enough to cause a severe burn 8 NEVER charge a frozen battery 10 CHARGER OPERATION Awarnine TO REDUCE THE RISK OF AN ELECTRIC SHOCK CONNECT ONLY TO A SINGLE PHASE PROPERLY GROUNDED 3 WIRE OUTLET REFER TO GROUNDING INSTRUCTIONS Acaution MAKE SURE THE BATTERY IS A RECHARGEABLE DEEP CYCLE BATTERY WITH THE PROPER RATED VOLTAGE FOR THIS CHARGER pancer TO PREVENT ELECTRICAL SHOCK DO NOT TOUCH UNINSULATED PARTS OF THE CHARGER DC OUTPUT CONNECTOR BATTERY CONNECTOR OR BATTERY TERMINALS MAKE SURE ALL ELECTRICAL CONNECTORS ARE IN GOOD WORKING CONDITION DO NOT USE CONNECTORS THAT ARE CRACKED CORRODED OR DO NOT MAKE ADEQUATE ELECTRICAL CONTACT USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY RESULT IN A RISK OF OVERHEATING OR ELECTRIC SHOCK Awarnine CHARGER IS NOT TO BE USED WHILE THE BATTERY POWERED EQUIPMENT IS OPERATING ATTENTION NE PAS UTILISER LE CHARGER PENDANT QUE L EQUIPMENT EST EN MAR
18. f 20 User s Manual VERTICAL JPTIONAL HANDLE THICKER METAL PLATE AS OPTIONAL BRACKET fon ddd ddd LLLI DL UM LA lla A Ain gu C AY N 2 2 4 X 5 D ay TY REF o o 9 e 5 i e 7 Figure 2 2 Charger Dimensions and Mounting Slot Locations Case 1 Summit Series 8 of 20 User s Manual P m LZ 8 g N IN A b L IRI N NS 2 LZ N 7 Figure 2 3 Charger Dimensions and Mounting Slot Locations Case 2 3 BATTERY TYPE This charger was factory configured to charge the type of battery indicated in the BATTERY field on the charger ratings label for example Wet The 13 and 14 characters in the charger part number available in the PART NO field on the charger ratings label provide the battery profile code for the primary battery profile For example charger part number 27790G05K5B1W1 has a primary battery profile code of W1 and charger part number 27790
19. harge PHASE A fault condition most commonly maximum time was met during a particular charge cycle phase start bulk plateau absorption finish etc MAX VOLTAGE Maximum voltage was met MIN VOLTAGE Minimum voltage was NOT met after a specified time from the start of the charge cycle MAX AMP HOURS Maximum amp hours for the overall charge cycle was Slow Blink met 1 Slow Blink Slow Blink MAX TIME Maximum time for the overall charge cycle was met Figure 12 1 Charger LED States Faults Fast Blink N A Slow Blink 1 I I Disconnecting the charger from the battery always clears fault If the charger was factory configured for on board use removing AC power from the charger also clears a fault If a fault cannot be cleared after taking appropriate corrective action contact your dealer for troubleshooting and or service Summit Series 16 of 20 User s Manual 13 TROUBLESHOOTING The charger was fully tested and calibrated before leaving the factory It was delivered ready to charge If properly installed the charger should require very little attention If improper charger operation occurs it will require repair by a qualified service technician Acaution DO NOT OPERATE THE CHARGER IF IT IS DAMAGED OR APPEARS TO BE MALFUNCTIONING PERSONAL INJURY OR DAMAGE TO THE CHARGER OR BATTERIES MAY RESULT DO NOT DISASSEMBLE THE CHARGER CONTACT YOUR DEALER INCORRECT REASSEMBLY MAY RESULT IN
20. it the power outlet contact Lester Electrical for the proper cord set terminating in an attachment plug of the proper configuration for the power outlet Summit Series 10 of 20 User s Manual Acaution TO REDUCE THE RISK OF ELECTRIC SHOCK OR FIRE DISCONNECT AC POWER FROM THE CHARGER BEFORE INSTALLING OR REMOVING UNIT DANGER NEVER ALTER THE AC POWER CORD OR PLUG PROVIDED IF IT WILL NOT FIT AN OUTLET OBTAIN THE CORRECT CHARGER IEC AC CORDSET FOR THE OUTLET OR HAVE A PROPER OUTLET INSTALLED BY A QUALIFIED ELECTRICIAN IMPROPER CONNECTION CAN RESULT IN A RISK OF ELECTRIC SHOCK If an extension cord is necessary it must be a 3 conductor No 12 AWG minimum heavy duty cord with ground It must also be in good electrical condition and as short as possible 50 ft 15m maximum Make sure that the pins on the plug of the extension cord are the same number size and shape as the AC power cord plug on the charger The use of an improper extension cord could result in a risk of fire or electrical shock Locate all cords so that they will not be stepped on tripped over or otherwise subjected to damage stress or accidentally disconnected VERIFY THAT THE AC POWER CORD IS FULLY ENGAGED IN THE IEC INLET AND CANNOT BE PULLED LOOSE BEFORE USING THE CHARGER Adancer RISK OF ELECTRIC SHOCK CONNECT THE AC SUPPLY CORD DIRECTLY TO A GROUNDED 3 WIRE OUTLET DO NOT TOUCH UNINSULATED PORTION OF DC OUTPUT TERMINALS OR BATTERY T
21. n Board Chargers On board chargers are designed to be mounted on electric vehicles equipment If the DC output is connected to a battery pack of the proper voltage a charge cycle automatically starts when the AC input plug is connected to AC power unless a safety period of time has not passed since the successful completion of the previous charge cycle Disconnecting the DC output from the battery pack is NOT REQUIRED to automatically start a new charge cycle 5 AC INPUT The charger has an AC input rating of 100 230 volts 50 60 hertz single phase The charger has an AC operating range of 90 264 volts 45 65 hertz Below 100 volts the charger may reduce output power The charger is equipped with an IEC inlet for the AC input power This allows the AC power cord to be selected with a proper plug to be compatible with the local wall outlets An optional AC cord clamp is available to retain the AC power cord The charger must be grounded to reduce the risk of electric shock and is equipped with an IEC inlet having an equipment grounding conductor and a grounding socket The installed AC power cord must be plugged into an outlet that is properly installed and grounded in accordance with all applicable electrical codes and ordinances If this charger includes the UL Listed symbol on its ratings label it is provided with a cord set for connection to outlets operating at nominal 120 volts or 240 volts as appropriate If the input plug does not f
22. out control signal will be active while a valid battery is connected to the charger The lockout control wire will be pulled down to battery negative when active Two 2 lockout control options exist If you are uncertain of which one your charger includes please contact your dealer Option 1 The lockout control wire is intended to be connected to the motor speed controller MSC lockout interlock input An internal pull up resistor to battery positive is included in order to pull the MSC lockout input high when the charger lockout control signal is not active Summit Series 11 of 20 User s Manual Option 2 An external DC relay coil with a minimum 2 kQ resistance can be connected in series from battery positive to the lockout control wire When the lockout control signal is active it will energize the relay The relay contacts can be used to lockout the vehicle using the key switch circuit etc Alternatively the lockout control wire can be connected to the motor speed controller MSC lockout interlock input A 10 kO 1 Watt pull up resistor to battery positive should also be connected to the MSC lockout input in order to pull this input high when the charger lockout control signal is not active 8 BATTERY TEMPERATURE SENSOR OPTIONAL Awarnine IT IS IMPORTANT TO MOUNT THE TEMPERATURE SENSOR ON THE BATTERIES FOR PROPER TEMPERATURE COMPENSATION The temperature sensor if present should be attached to a bat
23. teries between charges can recover some of the lost power range and life but some permanent loss should be expected 7 Cold batteries require more time to fully charge When the temperature falls below 65 the batte ries should be placed on charge as soon after use as possible Summit Series 12 of 20 User s Manual 8 The tops of batteries and battery hold downs must be kept clean and dry at all times to prevent excessive self discharge and the flow of current between the battery posts and frame Electrolyte spilled on batteries never dries or evaporates 9 All connections to batteries must be maintained clean and tight Due to heating and discharge rates bolted connections loosen over time Re tighten the connections twice yearly to the torques specified by the battery manufacturers 10 Follow all operating instructions cautions and warnings as specified in this manual on the charger in the battery manuals and in the vehicle manuals 9 1 Personal Safety Precautions 1 Have someone within the range of your voice and close enough to quickly come to your aid when you work near a lead acid battery 2 Ensure that ample fresh water and soap are nearby in case battery acid contacts your skin clothing or eyes 3 Wear complete eye and clothing protection Avoid touching your eyes while working near a battery 4 f battery acid contacts your skin or clothing wash immediately with soap and water If acid enters your eye imme
24. tery post near the center of the battery pack If the threaded stud is long enough above the battery jumper nut attach the probe with another nut Torque this nut to proper specifications If the stud is too short the nut holding the jumper wire will need to be removed Open or remove the load and charging circuits to the batteries Remove the nut and add the sensor then torque the nut to the proper specifications Then close or connect the load and charging circuits back to the batteries Securely fasten the temperature sensor cable to protect the sensor from being torn from the battery Secure the sensor cable to a fixed object to ensure the probe will not be pulled loose Use a cable tie mount on the battery or on the adjacent battery if necessary 9 PROPER CARE OF DEEP CYCLE LEAD ACID MOTIVE POWER BATTERIES Motive power battery packs are subjected to severe deep cycle duty on a daily basis Although these batteries are designed to withstand such duty the following precautions must be observed to obtain good performance and maximum cycle life Acaution ALWAYS WEAR PROTECTIVE EYE SHIELDS AND CLOTHING WHEN WORKING WITH BATTERIES BATTERIES CONTAIN ACIDS WHICH CAN CAUSE BODILY HARM DO NOT PUT WRENCHES OR OTHER METAL OBJECTS ACROSS THE BATTERY TERMINAL OR BATTERY TOP ARCING OR EXPLOSION OF THE BATTERY CAN RESULT 1 When installing new batteries be sure the polarity of each battery and the overall battery pack is correct Otherwise batter
25. the Charge Complete green LED or 2 the Charge Complete green LED beginning to blink slowly indicating a post charge phase The required charge time is affected by numerous factors including battery amp hour capacity depth of discharge battery temperature and battery age usage 9 After a charge cycle has completed disconnect the charger AC power cord from the outlet before operating the vehicle equipment 11 LED INDICATORS The charger includes three 3 LEDs to indicate charger status and fault information The functionality of the LEDs is outlined below If the charger is equipped with a remote LED assembly this assembly also includes three 3 LEDs with identical functionality CHARGE STATUS yellow Indicates charge cycle status See Figure 11 1 for descriptions of the possible states CHARGE COMPLETE green Indicates when a charge cycle completes successfully when an extended Balance Equalize charge cycle phase is active or when a post charge phase is active See Figure 11 1 for descriptions of the possible states FAULT red Indicates when a charger or battery fault has occurred See the FAULTS section Description Bulk Start charge cycle phase constant power or Slew Elk constant current Absorption Plateau charge cycle phase constant voltage Greater than 80 charged Solid On Finish charge cycle phase constant current Not all charge profiles include a Finish phase Balance Equalize phase
26. under voltage 27790 27800 28000 48 28110 28120 28230 36 Vdc 27940 24 Vdc 27790 27800 28000 72 28110 28120 28230 54 Vdc 27940 36 Vdc 10 Vdc 28110 28120 640 W 27790 27800 27940 700 W 28230 950 W 28000 1050 W 27790 27800 13A 28110 28120 14 5 28000 19 5 A 28230 21 27940 25A 27790 27800 28110 28120 14 5 28000 28230 21A 27940 25A Wet flooded AGM gel deep cycle lead acid lithium ion custom See Section 3 for additional details Current limit short circuit reverse polarity under voltage over voltage wrong battery voltage Charge Complete green Charge Status yellow Fault red Optional Pulls down to battery neg when active See Section 7 for options and additional details Optional Optional See Figures 2 2 and 2 3 Case 1 9 Ibs 4 1 kg Case 2 12 165 5 5 kg Natural convection no fan IEC 60320 C16 inlet with cord clamp Shelf wall bulkhead threaded steel rod with optional handle hook with optional handle See Figure 2 1 for additional details Optional IP66 NEMA 4 25 degrees C to 60 degrees C 13 degrees F to 140 degrees F See datasheet for temperatures and mounting orientations where power reduction occurs 40 degrees C to 85 degrees C 40 degrees F to 185 degrees F Summit Series 18 of 20 User s Manual NOTES Summit Series 19 of 20 User s Manual Represented By 3 9 2 5 1 ELECTRICAL
27. y and or charger damage can result 2 New batteries should be given a full charge before their first use because it is difficult to know how long the batteries have been stored 3 New batteries and older batteries that have been in storage are not capable of their rated output until they have been discharged and charged a number of times Consult the manufacturer of your batteries for more information 4 DO NOT EXCESSIVELY DISCHARGE THE BATTERIES Excessive discharge can cause polarity reversal of individual cells resulting in complete failure shortly thereafter 5 Maintain the proper electrolyte level of wet flooded batteries by adding water when necessary Distilled or deionized water is best for battery life Never allow the electrolyte level to fall below the top of the battery plates Electrolyte levels lower during discharge and rise during charge Therefore to prevent the overflow of electrolyte when charging it is mandatory that water be added to cells AFTER they have been fully charged do not overfill Old batteries require more frequent additions of water than new batteries 6 Hard crystalline sulfates form when batteries in storage are not maintained in a charged active state Internal self discharge can bring about the start of this condition in as little as three days in warm temperatures Batteries not maintained and allowed to sit in storage will self discharge sulfate and lose capacity Repeated charging without using the bat
28. y connector receptacle The charger will start automatically which is indicated by the Charge Status yellow LED beginning to blink slowly 3 If the charger must be disconnected from the battery while a charge cycle is in progress first disconnect the AC power cord from the AC outlet Do not disconnect the charger DC output connector plug from the battery while a charge cycle is in progress 4 The charge cycle 8096 point is indicated by the Charge Status yellow LED beginning to blink quickly 5 The Finish charge cycle phase is indicated by the solid illumination of the Charge Status yellow LED Not all charge profiles include a Finish phase 6 An extended Balance Equalize charge cycle phase is indicated by the Charge Complete green LED beginning to blink quickly Not all charge profiles include a Balance Equalize phase 7 The charger automatically terminates the charge cycle when a battery reaches full charge which is indicated by 1 the solid illumination of the Charge Complete green LED or 2 the Charge Complete green LED beginning to blink slowly indicating a post charge phase The required charge time is affected by numerous factors including battery amp hour capacity depth of discharge battery temperature and battery age usage 8 After a charge cycle has completed disconnect the charger DC output connector plug from the battery connector receptacle by firmly grasping both connectors and pulling them straight apart 10
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