USER`S MANUAL - Lester Electrical
Contents
1. 10 8 2 DC OUTPUT FUSE u u uuu so aan cor kv ad rete 10 9 PROPER CARE DEEP CYCLE MOTIVE POWER BATTERIES 11 9 1 Personal Safety Precautions J U T T 11 10 CHARGER OPERATION U ede Sb idu J 12 10 1 User 1 dide eub nbi bleue Dit kawsas Eee deett 14 10 2 Low Voltage u 15 10 3 Self Diagnostic and Faults nuno ntu nu ununi 15 11 LOCKOUT INTERLOCK RELAY OPTION J 16 12 ri iB nudc B 16 12 1 Check Charger Area 16 12 2 Visual Cer Teile M 4 16 12 3 16 13 TROUBLESHOOTING AND 17 LIMITED WARRANTY2. 19 X Series 3 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 POINT OUT SAFETY PRECAUTIONS DANGER 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 Aunstructions IMPORTANTES CONCERNANT LA SECURITE 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 LEAD ACID BATTERIES OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE BEFORE CHARGING A
3. X Series 7 of 20 User s Manual 5 1 Chargers Off board chargers designed to be used shelf or portable applications They include rubber feet 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 unless a storage mode condition has been met Disconnecting the DC output from the battery pack IS REQUIRED to automatically start a new charge cycle 5 2 On Board Chargers On board chargers are designed to be mounted on electric vehicles equipment They include steel feet with a pattern that provides numerous mounting options see Section 6 1 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 6 LOCATION AND INSTALLATION Awarnine DO NOT INSTALL THE CHARGER ON OR NEAR FLAMMABLE MATERIALS POSITION THE CHARGER ON A FOUNDATION OF STONE BRICK CONCRETE OR GROUNDED METAL Awarnine CHARGERS CAN IGNITE FLAMMABLE MATERIALS AND VAPORS DO NOT USE NEAR
4. 3 414 X Series SCR Battery Charger USER S MANUAL Industrial Battery Charger Important Safety Installation Operation and Maintenance Instructions Leslee Electrical M www LesterElectrical com CHARGER RATINGS LABEL The ratings label is located on the back of the charger The label provides the model MODEL serial number SERIAL NO AC input configuration AC VOLTS AC AMPS PHASE and HERTZ and DC output specifications CELLS DC VOLTS DC AMPS and AMP HRS of the charger TYPE indicates the factory configured battery type and if the charger is configured for on board operation An example charger ratings label is provided below LESTER ELECTRICAL SERIAL 160900001 625 West A Street MODEL 127030 84 151 1 Lincoln 68522 USA 27030 Industrial Battery Charger AC VOLTS AC AMPS PHASE HERTZ 120 12 5 1 60 m Please fill in the blank label that is provided below with the information from the ratings label on your charger for future reference LESTER ELECTRICAL 2 SERAL 625 west Street Lincoln NE 68522 USA Industrial Battery Charger AC VOLTS AC AMPS HERTZ Document any configuration or settings changes that are made by marking the ratings label your charger an additional label or tag attached to your charger SAVE
5. The area around the charger must remain clean cool dry and well ventilated Check for obstructions to airflow clearances or other violations of the requirements in Section 5 12 2 Visual Inspections Check the charger for any physical failures such as loose contacts or hardware excess wear or damage Darkened or hot terminals should be tightened or replaced 12 3 Battery Conditions Acaution CHECK THE DC CONNECTIONS FROM THE CHARGER TO THE BATTERY AND MAKE SURE THEY ARE TIGHT AND CLEAN TIGHTEN AND OR CLEAN IF NEEDED FAILURE TO DO SO COULD CAUSE MALFUNCTION FIRE OR EXPLOSION Batteries must be well maintained for the charging system to operate properly Follow battery manufacturer instructions for battery maintenance Check for loose connections or corrosion DC connections may become corroded over time If the connections become corroded they should be cleaned as recommended by the battery manufacturer After the connections have been cleaned a battery connection treatment should be applied to help prevent corrosion from reoccurring Contact the battery manufacturer for their recommendations Periodic cleaning and watering of non sealed batteries is very important Logging the water usage of non sealed batteries is useful As a battery ages it will use more water X Series 16 of 20 User s Manual 13 TROUBLESHOOTING SERVICE Acaution DO NOT DISASSEMBLE THE CHARGER TAKE IT TO A QUALIFIED SERVICE TECHNICIAN W
6. The major factors affecting the required charge time are the amp hour capacity depth of discharge temperature and age usage of the battery pack Completion of the charge cycle is indicated by 1 the solid illumination of the Charge Status LED on the user interface or 2 if the charger is configured for a post charge mode the Charge Status LED displaying a repeating pattern of long on approximately 4 seconds followed by short off approximately 1 second If the charger is in a post charge mode press the Stop Start button on the charger user interface to terminate the post charge mode which is indicated by the solid illumination of the Charge Status LED Disconnect the charger DC output connector from the battery pack connector by grasping both connectors and pulling them straight apart If the charger DC output connector remains connected to the battery pack after the charger automatically terminates the charge cycle and the charger has AC power available it will enter a storage mode where it periodically performs a maintenance charge cycle Storage mode is a feature of specific charge battery profiles Contact your dealer to determine if your charger includes a storage mode On Board Charger Operation 1 With the charger AC input plug disconnected from the AC outlet receptacle connect the DC output connector to the battery pack if not already connected Connect the charger AC input plug to single pha
7. 6 the charger is in a post charge mode press Stop Start button on the charger user interface to terminate the post charge mode which is indicated by the solid illumination of the Charge Status LED 7 Disconnect the charger AC input plug from the outlet 8 If the charger DC output connector remains connected to the battery pack connector after the charger automatically terminates the charge cycle and the charger has AC power available it will enter a storage mode where it periodically performs a maintenance charge cycle Storage mode is a feature of specific charge battery profiles Contact your dealer to determine if your charger includes a storage mode 10 1 User Interface The user interface Figure 10 1 1 includes an ammeter for monitoring the DC output current of the charger Additionally the user interface includes 3 buttons and 2 LEDs light emitting diodes Figure 10 1 2 and Figure 10 1 3 describe the LED and button functions respectively The user interface also includes an AC input circuit breaker and DC output fuse CHARGE STATUS X Series SCR Battery Charger PRESS SELF DIAGNOSTIC Made in USA ALTERNATE LEG CONSTRUCTION Figure 10 1 1 X Series User Interface Button Description Stop Start Stops a charge cycle or post charge mode that is in progress Starts a new charge cycle if pressed when one is not in progress Low Voltage Manually starts a charge cycle for a battery with a v
8. NEAR BATTERIES DO NOT DISCONNECT THE CHARGER DC OUTPUT FROM THE BATTERIES WHILE THE CHARGER IS OPERATING IF THE CHARGE CYCLE MUST BE INTERRUPTED PRESS THE STOP START BUTTON TO TERMINATE THE CHARGE CYCLE BEFORE DISCONNECTING THE CHARGER DC OUTPUT FROM THE BATTERIES KEEP SPARKS FLAME AND SMOKING MATERIALS AWAY FROM BATTERIES 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 PLUG FROM THE BATTERY RECEPTACLE WHILE A CHARGE CYCLE IS IN PROGRESS THE RESULTING ARCING AND BURNING OF THE PLUG AND RECEPTACLE COULD CAUSE THE BATTERIES TO EXPLODE IF THE CHARGER MUST BE STOPPED WHEN A CHARGE CYCLE IS IN PROGRESS FIRST PRESS THE STOP START BUTTON ON THE USER INTERFACE THEN DISCONNECT THE CHARGER DC OUTPUT PLUG FROM THE BATTERY RECEPTACLE CAUTION TO 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 Off Board Charger Operation 1 With the charger DC output connector disconnected from the battery pack connect the AC input plug to a single phase 120V 60 Hz AC outlet recept
9. jumper position Profile 2 is the secondary battery profile If changed from the factory configured jumper position Profile 1 mark the charger ratings label or add an additional label or tag Secon lary Profile 0 Figure 4 2 Setting the Internal Battery Profile Jumper Determines Battery Acaution THIS CHARGER IS FOR USE ONLY ON RECHARGEABLE DEEP CYCLE LEAD ACID BATTERY SYSTEMS OF THE SAME TYPE AS THE SELECTED BATTERY PROFILE BATTERIES IMPROPERLY MATCHED WITH THE CHARGER MAY BURST CAUSING PERSONAL INJURY AND DAMAGE TO BATTERIES OR CHARGER Battery manufacturers frequently use the same battery cases for different battery types Wet 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 5 OFF BOARD SHELF VERSUS ON BOARD BUILT IN CHARGERS X Series chargers are available in either off board or on board configurations Chargers configured for on board use are denoted as such in the type field on the charger ratings label for example wet onbrd
10. C Cordset Kit 21307 08S 21307 08S 21307 08S 21307 08S 21307 08S 21307 08S 21307 08S 9 DC Cordset Kit Contact Your Sales Representative Misc Wiring Kit N A LEDs Control Cables 37441S 37442S 37441S 37441S 37441S 37441S 37441S Misc Wires N A Lockout Relay 376766 37676S 376765 37676 376765 376765 376765 X Series 17 of 20 User s Manual WIRING DIAGRAMS MODEL 27020 ONLY X Series 18 of 20 User s Manual LIMITED WARRANTY Lester Electrical warrants each new Lester Battery Charger for defects in material and workmanship for a period of two 2 years from the date of manufacture of the complete unit Repairs can be made at the Lester factory To do so first obtain a Return Material Authorization number by calling the Service Department of Lester Electrical 402 477 8988 or by e mailing service lesterelectrical com and send the defective unit with transportation charges prepaid to Lester Electrical 625 West A Street Lincoln NE 68522 1794 USA Attention Service Department RMA For repairs made at other than the Lester factory Lester will provide only the replacement parts Defective parts should be sent with transportation charges prepaid to the Lester factory at the address noted above If the unit or parts are found in the reasonable judgment of Lester to be defective in material or workmanship repair or replacement will be made by Lester without charge for parts or la
11. CREATE SPARKS NEAR THE BATTERY VENTILATE THE AREA WHEN THE BATTERY IS CHARGING IN AN ENCLOSED PLACE A 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 WARNING ONLY YOUR DEALER S QUALIFIED SERVICE TECHNICIANS 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 YOUR DEALER S QUALIFIED SERVICE TECHNICIAN EXAMINE AND REPAIR AS NEEDED A WARNING DO NOT DISASSEMBLE THE CHARGER HAVE THE CHARGER EXAMINED BY YOUR DEALER S QUALIFIED SERVICE TECHNICIAN INCORRECT RE ASSEMBLY OF THE CHARGER MAY RESULT IN AN EXPLOSION ELECTRIC SHOCK OR FIRE A CAUTION MAKE SURE THE BATTERY SYSTEM HAS THE PROPERLY RATED VOLTAGE AMP HOURS AND TYPE WET AGM GEL ETC FOR THIS CHARGING SYSTEM SAVE THESE INSTRUCTIONS X Series 5 of 20 User s Manual 1 INTRODUCTION This X Series battery charger is an advanced microprocessor based silicon controlled rectifier SCR charger designed to optimize both daily battery capacity and overall battery life It plugs directly into standard 120V 15A 60 Hz AC outlets receptacles for use in off board shelf or on board built in applications The charger is natural convection cooled with no moving parts It wa
12. FUELS GRAIN DUST SOLVENTS THINNERS OR OTHER FLAMMABLES The charger may have been attached to a plywood board in the factory to protect it during shipping If so remove the plywood shipping board before installation and operation of the charger Proper installation of the charger is important in order to achieve good performance and to prevent damage to the charger and batteries The charger should be located in a clean cool dry and well ventilated area To permit free airflow for convection cooling allow 2 inches 5 08 cm minimum between the charger ventilation openings and any walls or other objects Do not obstruct the airflow space around and beneath the charger Do not allow clothing blankets or other materials to cover the charger Install the charger in an area where the temperatures will remain within the range of 4 F to 113 F 20 C to 45 C and the relative humidity will remain below 95 percent Exceeding these ranges will reduce the current capacity and possibly the service life of the charger If the charger will be operated outside of these ranges contact your dealer to verify if it will withstand these conditions and perform at the needed capacity 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 manner Contact your dealer A WARNING REPLACE WORN DAMAGED OR CUT ELECTRICAL CORDS AND PLU
13. GS IMMEDIATELY A WARNING KEEP DRY DO NOT EXPOSE TO RAIN OR SPRAY FOR STORAGE KEEP CHARGER IN A BUILDING NE PAS EXPOSER A LA PLUIE X Series 8 of 20 User s Manual 6 1 Mounting On board X Series chargers designed to be mounted on electric vehicles equipment They include steel feet with a pattern that provides numerous mounting options A dimensional drawing of the on board mounting pattern is provided in Figure 6 1 1 2 aa 2 Figure 6 1 1 On Board Mounting Pattern 7 AC INPUT This charger must be connected to a single phase nominal 120 Vac 60 Hz AC power source with a voltage of 110 Vac to 132 Vac charge times increase at lower AC voltages The frequency must be 57 Hz to 63 Hz Circuit breaker or fuse protection for the AC outlet to which the charger is connected should allow 15A per charger Do not overload an electrical outlet This charger must be grounded to reduce the risk of electric shock It is equipped with an AC cable with an equipment grounding conductor and a grounding type connector The connector must be plugged into an appropriate outlet that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances DANGER IMPROPER CONNECTION OF THE GROUNDING CONDUCTOR CAN RESULT IN A RISK OF ELECTRIC SHOCK DO NOT REMOVE GROUNDING PRONG FROM PLUG The conductor with insulation having an outer surface
14. HEN SERVICE OR REPAIR IS REQUIRED INCORRECT REASSEMBLY MAY RESULT IN A RISK OF ELECTRIC SHOCK OR FIRE DANGER TO REDUCE THE RISK OF ELECTRIC SHOCK ALWAYS DISCONNECT BOTH THE POWER SUPPLY CORD AND THE OUTPUT CORD BEFORE ATTEMPTING ANY MAINTENANCE OR SERVICE A WARNING DO NOT OPERATE THE CHARGER IF IT IS MALFUNCTIONING PERSONAL INJURY OR PROPERTY DAMAGE COULD RESULT The charger was fully tested and calibrated before leaving the factory properly installed the charger should require very little attention require repair by a qualified service technician lt gt W lt lt 9 SERVICE PARTS LIST It was delivered ready to charge If If improper charger operation occurs it will ROE eS Pait Description aoe en sey 25A TA 1 Assembly 087765 087995 087765 087745 087765 087745 087765 2 Relay Board Assembly 27105 01S 27105 01S 27105 02S 27105 02S 27105 03S 27105 03S 27105 04S 3 SCR Assembly Kit 37204S 37819S 37204S 37082S 37204S 37082S 37204S 4 Control Board Assembly 26815 01S 26815 02S 26815 00S 26815 00S 26815 00S 26815 00S 26815 00S 5 AC Circuit Breaker 35363S 31847S 31847S 34882S 34882S 34882S 34882S 6 Ammeter 16369S 20726S 16369S 16823S 16369S 16823S 16895S Misc Switch Kit 7 Stop Start Low 37446S 37446S 37446S 37446S 37446S 37446S 37446S Voltage Self Diagnostic 8 A
15. NY 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 CAUTION DO NOT EXPOSE TO RAIN INDOOR USE ONLY ATTENTION NE PAS EXPOSER LA PLUIE 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 X Series 4 of 20 User s Manual 14 15 16 17 18 19 20 21 22 WARNING HAZARD OF ELECTRIC SHOCK WARNING LEAD ACID BATTERIES GENERATE EXPLOSIVE GASES TO PREVENT ARCING OR BURNING NEAR BATTERIES DO NOT DISCONNECT DC CHARGING CORD FROM BATTERIES WHEN THE IS OPERATING PUSH THE STOP START BUTTON TO TURN CHARGER OFF KEEP SPARKS FLAME AND SMOKING MATERIALS AWAY FROM BATTERIES 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 WARNING BATTERIES PRODUCE HYDROGEN GAS WHICH CAN EXPLODE IF IGNITED NEVER SMOKE USE AN OPEN FLAME OR
16. THIS MANUAL Keep it in a location where it is available to anyone who may operate the charger X Series 2 of 20 User s Manual TABLE CONTENTS CHARGER RATINGS LABEL 4 Ya au Roa DE E EX ieiuna died 2 5 2 222 asss 3 1 Au e 6 2 RECEIVING THE CHARGER IE dE an o ad 6 Jj u mau musu a haut m tausug man uw Died 6 A gt BATTERY TYPE u uu u uuu n uqun ui a s q aasan asp a pu usss 6 5 OFF BOARD SHELF VERSUS ON BOARD BUILT IN CHARGERS 7 5 1 Off Board Chargers Leda did aba ce bridal d T 8 5 2 On Board Chargers 8 6 LOCATION AND INSTALLATION U u nnns 8 6 1 On Board Mounting 9 f AG INPUT Su 9 8 DC OUTPUT saiia 10 8 1 ROUND MOLDED 3 PIN
17. USE ELECTRICAL SHOCK SERIOUS INJURY OR DEATH This charger is designed to charge deep cycle lead acid batteries of wet flooded AGM absorbed glass mat or gel design The charger is factory configured to charge the type of battery indicated in the TYPE field on the charger ratings label for example Wet Additionally the charger includes a secondary battery profile available via an internal jumper on the control board The last four 4 characters in the charger part number available in the MODEL field on the charger ratings label provide the battery profile codes for both the primary and secondary battery profiles For example charger part number 27030C84F181W14A1 has a primary battery profile code of W1 and a secondary battery profile code of Figure 4 1 lists standard battery profile codes and their corresponding battery profiles If a battery profile code for your charger is not listed in Figure 4 1 please contact your dealer regarding which battery profiles are available on your charger X Series 6 of 20 User s Manual Number Battery Profile Code Battery Profile W1 Wet standard A1 AGM standard G1 Gel standard Figure 4 1 Standard Battery Profile Codes and Their Corresponding Battery Profiles To change the active battery profile on your charger remove the charger cover and position the jumper as shown in Figure 4 2 Profile 1 is the primary battery profile and the factory configured
18. acle if not already connected X Series 12 of 20 User s Manual 2 Connect the charger DC output connector to the battery pack connector by firmly grasping both connectors and plugging them straight together The charger will start automatically which is indicated by the blinking Charge Status LED on the user interface on for approximately 1 second followed by off for approximately 1 second If the charger does not automatically start because the battery is overly discharged the Low Voltage Start button on the user interface can be used to manually start a charge cycle See Section 9 2 for details If the charger must be disconnected from a battery pack while a charge cycle is in progress press the Stop Start button on the user interface to stop the charge cycle before disconnecting the DC output connector from the battery pack Do not disconnect the DC output connector from a battery pack while a charge cycle is in progress The resulting arcing and burning of the connectors could cause the battery to explode Monitor the ammeter on the charger user interface for the correct charge current The initial charge current could vary several amps from the start current listed in the specifications depending on both the condition of the battery pack and its depth of discharge The charger automatically terminates the charge cycle when the battery pack reaches charge necessary charge time is affected by numerous factors
19. attery or too high incorrectly sized battery Connect a battery that is not overly discharged with a cell count CELLS and DC voltage DC VOLTS equal to those listed on the charger ratings label to the charger and press the Self Diagnostic button again OR A timer fault has occurred For example the maximum charge cycle timer has expired or the maximum allowable amp hours returned has been reached Ensure that a battery in good working condition with an amp hours rating AMP HRS within the range listed on the charger ratings label is connected to the charger Control Board The control board is not functioning properly Current Sense The current sense is not functioning properly AC Input An AC input issue exists Ensure that the charger AC power cord is connected to a single phase 120V 60 Hz outlet that is properly powered Ensure that the charger AC circuit breaker on the user interface has not tripped If it has press to reset it Otherwise the charger is not functioning properly X Series 15 of 20 User s Manual DC Output A DC output issue exists Ensure that the charger DC fuse on the user interface is not blown Otherwise the charger is not functioning properly It is possible that the charger is still able to charge but with reduced current Jumper Missing The internal charge profile jumper is missing See Section 4 for details 11 LOCKOUT INTERLOCK RELAY OPTION On board X Series chargers can be ordere
20. bor Repair or replacement will be at the discretion of Lester with replacements being made using current models or parts performing the equivalent function Labor charges other than those incurred at the Lester factory are not covered under this warranty All expenses associated with delivering defective items to the Lester factory and the expense of returning repaired or replaced items from the Lester factory to the owner will be paid for by the owner All warranty work accomplished at the Lester factory will be completed with a reasonable time after receipt of defective items This warranty does not cover any semiconductor parts such as diodes which are vulnerable to electrical overloads beyond the control of Lester Warranty on parts not manufactured by Lester which include but are not limited to timers and ammeters is limited to the period specified in the original manufacturer s warranty This warranty does not cover any charger that has been subject to misuse neglect negligence or accident or operated in any way contrary to instructions specified on the charger case and in the owner s manual No claim of breach of warranty shall be cause for cancellation of the contract of sale of any Lester charger Lester assumes no responsibility for loss of time inconvenience or other damage consequential or otherwise resulting from a defective charger All implied warranties including merchantability are limited in duration to the two years from dat
21. d with an optional internal relay that can be used to provide lockout interlock functionality The two 2 exposed terminals of the dry contact relay are CONNECTED when AG power is NOT PRESENT the charger and the terminals are DISCONNECTED when AC power IS PRESENT at the charger The relay is rated for up to 10 amps 12 MAINTENANCE Awarnine DISCONNECT BOTH AC AND DC POWER FROM THE CHARGER BEFORE PERFORMING ANY MAINTENANCE CONTACT WITH LIVE COMPONENTS WITHIN THE CHARGER COULD CAUSE ELECTRICAL SHOCK SERIOUS INJURY OR DEATH Acaution KEEP CHARGER CLEAN AND DRY INSIDE AND OUT FAILURE TO DO SO MAY CAUSE DAMAGE OR FAILURE OF CHARGER The charger requires minimal maintenance It should be kept clean Twice a year or as often as the cleanliness of the area may dictate the interior of the charger should be thoroughly blown clean with dry compressed air The components of the charger are cooled by natural convection If dust and debris are allowed to build up they will restrict airflow and could cause components to overheat Always be careful not to bump wiring or components This could cause loose connections and failures Moisture may cause electrical shorting and or corrosion It may also combine with dust and debris making them more difficult to remove Do not use liquids to clean the charger Liquids could cause damage Compressed air should be used to clean dust and debris from the charger and its components 12 1 Check Charger Area
22. e of manufacture warranty period Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on how long an implied warranty lasts so the above limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Lester s obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective items Lester issues this warranty in good faith and with full confidence in the workmanship and quality of Lester products X Series 19 of 20 User s Manual Represented 357414 WU Electrical 37414H X Series 20 of 20 User s Manual
23. icinity of a battery 6 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 X Series 11 of 20 User s Manual 10 CHARGER OPERATION WARNING 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 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 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 15 TO BE USED WHILE THE BATTERY POWERED EQUIPMENT IS OPERATING Aa Ne pas utiliser le charger pendant que l equipment est en marche WARNING LEAD ACID BATTERIES GENERATE GASES WHICH CAN BE EXPLOSIVE TO PREVENT ARCING OR BURNING
24. irst use because it is difficult to know how long the batteries have been stored 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 DO NOT EXCESSIVELY DISCHARGE THE BATTERIES Excessive discharge can cause polarity reversal of individual cells resulting in complete failure shortly thereafter 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 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 batteries between charges can recover some of the lost power range and life but some permanent loss should be e
25. oltage too low to automatically Start start See Section 9 2 for details Self Diagnostic Initiates self diagnostic test of the charger See Section 9 3 for details Figure 10 1 2 User Interface Buttons LED Description 1 Blinks during a charge cycle on for approximately 1 second followed by off for approximately 1 second 2 Lights solid when a charge cycle completes 3 Ifthe charger is configured for a post charge mode displays a repeating pattern of long on approximately 4 seconds followed by short off approximately 1 second during post charge mode 4 Used in conjunction with the Self Diagnostic LED to indicate the result of a self diagnostic test or a charge cycle fault Used in conjunction with the Charge Status LED to indicate the result of a self diagnostic test or a charge cycle fault See Section 9 3 for details Charge Status Self Diagnostic Figure 10 1 3 User Interface LEDs X Series 14 of 20 User s Manual 10 2 Low Voltage Start The Low Voltage Start button manually starts a charge cycle for a battery with a voltage too low to automatically start as low as 1V You should press and hold the button for 5 to 10 seconds If the battery voltage is 1V or above the Charge Status LED will begin blinking while you are holding the button If the Charge Status LED stops blinking after you release the Low Voltage Start button repeat pressing and holding the button f
26. or another 5 to 10 seconds 10 3 Self Diagnostic and Faults The Self Diagnostic button should be used when you suspected that the charger is not functioning properly Pressing this button initiates a self diagnostic test A properly sized battery that is not overly discharged must be connected to the charger for the self diagnostic test to execute The Self Diagnostic and Charge Status LEDs indicate the result of the self diagnostic Figure 9 3 1 lists the possible combinations of LED states and the respective self diagnostic results that they indicate The self diagnostic results are explained below f a fault occurs while the charger is in use the same results will be indicated using the Self Diagnostic and Charge Status LEDs In the event that the self diagnostic returns a result other than Self Diagnostic Passed contact a qualified service technician and provide them with the self diagnostic result Self Diagnostic LED Charging LED Self Diagnostic State State Result Off Off Self Diagnostic Passed Blink Blink Battery Voltage Solid Off Dim Control Board Blink Solid Current Sense Solid Blink AC Input Solid Solid DC Output Blink Off Jumper Missing Figure 9 3 1 Self Diagnostic Results Self Diagnostic Passed The self diagnostic test was successful and no issues were identified with the charger Battery Voltage The DC battery voltage is too low low battery condition or incorrectly sized b
27. per extension cord could result in a risk of a fire and electrical shock If an extension cord is needed use a three conductor No 14 AWG or larger cord that is grounded properly wired and in good electrical condition and keep the cord as short as possible Make sure that the pins on the connector of the extension cord are the same number size and shape as those on the AC connector on the charger Locate all extension cords so that they will not be stepped on tripped over or otherwise subjected to damage or stress The charger includes an AC input circuit breaker to protect the charger and the system 8 DC OUTPUT Only charge battery packs with cell counts CELLS and DC voltages DC VOLTS equal to those listed on the ratings label on the back of the charger The DC output cordset includes a commonly used connector plug The polarity of the charger connector plug must be the same as the battery connector receptacle The marked BLACK DC cable must be connected to the battery negative and the marked WHITE DC cable must be connected to the battery positive charger will not operate if the polarity is reversed 8 1 ROUND MOLDED 3 PIN PLUG If the DC cordset includes the round molded 3 pin plug for use with Club Car amp vehicles it is important to understand that this charger is intended for use with vehicles without an onboard computer OBC If the charger is connected to a vehicle with an onboard com
28. puter the charger will not start a charge cycle In addition to the battery negative and battery positive 4 pins this plug includes a third pin This third pin is connected to battery negative inside the charger It can be used with an optional external relay that can be installed in the vehicle to provide lockout interlock functionality Club Car is a registered trademark of Club Car Inc 8 2 DC OUTPUT FUSE The DC output fuse is a fast acting fuse used to protect the charger and the system USE ONLY THE CORRECT SIZE IDENTICAL TYPE REPLACEMENT FUSES FUSES ARE AVAILABLE FROM A QUALIFIED SERVICE TECHNICIAN X Series 10 of 20 User s Manual 9 PROPER CARE DEEP CYCLE MOTIVE POWER BATTERIES Motive power batteries 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 2 When installing new batteries be sure the polarity of each battery and the overall battery pack is correct Otherwise battery and or charger damage can result New batteries should be given a full charge before their f
29. s factory configured to charge wet AGM or gel deep cycle lead acid batteries and includes an internal jumper that can be used to select between two battery profiles in the field This charger features fully automatic operation with a manual stop start button low battery voltage start button self diagnostic button ammeter and status LEDs Figure 1 1 provides specifications for the X Series product line Model DC Output DC Output Amp Hour Rating AC Input Shipping Weight Number Volts Amps Rate 12 Hrs Amps Approx Lbs 26900 150 305 27020 250 5100 9 9535 Figure 1 1 X Series Product Line Specifications 2 RECEIVING THE CHARGER 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 3 STORAGE When the charger is stored prior to being installed and powered up it must be stored indoors in a clean and dry environment where the temperatures will remain within the range of 40 F to 150 40 C to 65 C The charger should be stored upright in the shipping carton that it was shipped in This will help protect the charger from dust and abrasion It should be stored in an area where it is not likely to be damaged Do not stack anything on top of the charger 4 BATTERY TYPE WARNING DISCONNECT BOTH AC AND DC POWER FROM THE CHARGER BEFORE OPENING THE CASE CONTACT WITH LIVE COMPONENTS WITHIN THE CHARGER COULD CA
30. se 120V 60 Hz AC outlet charger will start automatically which is indicated by the blinking Charge Status LED on the user interface on for approximately 1 second followed by off for approximately 1 second If charger does not automatically start because the battery pack is overly discharged the Low Voltage Start button on the user interface can be used to manually start a charge cycle See Section 10 2 for details Ifthe charge cycle must be terminated early press the Stop Start button on the charger user interface Monitor the ammeter on the charger user interface for the correct charge current The initial charge current could vary several amps from the start current listed in the specifications depending on both the condition of the battery pack and its depth of discharge The charger automatically terminates the charge cycle when the battery pack reaches charge necessary charge time is affected by numerous factors The major factors affecting the required charge time are the amp hour capacity depth of discharge temperature and age usage of the battery pack Completion of the charge cycle is indicated by 1 the solid illumination of the Charge Status LED on the user interface or 2 if the charger is configured for a post charge mode the Charge Status LED displaying a repeating pattern of long on approximately 4 seconds followed by short off approximately 1 second X Series 13 of 20 User s Manual
31. that is green with or without a yellow stripe s is the equipment grounding conductor If repair or replacement of the AC cable or connector is necessary do connect the equipment grounding conductor to a live terminal Contact your dealer This charger is equipped with a grounding connector as illustrated in Figure 7 1 A for use on a nominal 120 Vac 60 Hz circuit A temporary adapter as illustrated in Figures 7 1 B and C may be used to plug this connector into a two pole receptacle as shown in Figure 7 1 C if a properly grounded outlet is not available NOTE use of an adapter as shown in Figures 7 1 B and C is NOT permitted in Canada The temporary adapter should be used only until a properly grounded outlet can be installed by a qualified electrician The green colored rigid ear extending from the adapter must be connected to a permanent ground such as a properly grounded outlet box DANGER BEFORE USING THE ADAPTER AS ILLUSTRATED BE CERTAIN THAT THE CENTER SCREW OF THE OUTLET PLATE IS GROUNDED X Series 9 of 20 User s Manual GROUNDING METHODS A B C COVEROF F ADAPTER GROUNDED A pon OUTLET BOX lt lt i CONNECTED O R OF GROUNDED BLADE GROUNDED A OUTLET Figure 7 1 Grounding Methods NOTE Use of an adapter as shown in Figures B and C is NOT permitted in Canada Use of an extension cord with the charger should be avoided Use of an impro
32. xpected Cold batteries require more time to fully charge When the temperature falls below 65 F the batteries should be placed on charge as soon after use as possible 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 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 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 If battery acid contacts your skin or clothing wash immediately with soap and water If acid enters your eye immediately flush your eye with running cold water for at least 10 minutes and get medical attention immediately 5 NEVER smoke or allow a spark or flame to be in the v
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