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Troubleshooting Guide

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31039B

TROUBLESHOOTING GUIDE

LESTRONIC II BATTERY CHARGER

FOR MOTIVE POWER BATTERIES

PLEASE SAVE THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS

For correct operation of the equipment, it is important to read and be familiar

with this entire manual before installing and operating the charger.

DO NOT DISCARD THIS MANUAL AFTER READING.

LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS:

BECOME ALERT—YOUR SAFETY IS INVOLVED.

  IF YOU DO NOT FOLLOW THESE

SAFETY INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR.

INTRODUCTION

The Lestronic II battery charger is designed to
recharge deep-cycle, lead-acid batteries.  A
ferroresonant transformer is used to provide a highly
reliable, line compensating unit with a minimum of
moving parts, designed for long, trouble-free service.
A patented electronic timer turns the charger on and
off automatically.  This electronic timer determines
full charge of the batteries by measuring the rate at
which the battery voltage increases during charge.
When the voltage stops rising, the battery is fully
charged and the charger turns off.

PROPER CARE OF 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.

CAUTION:  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 overall battery pack
is correct.  Due to the electrical characteristics of
this charger, it is possible to improperly hook up
the batteries and not blow the fuse when
charging.  Battery 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.

Limit the use of new batteries for the first 20
cycles.  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.

4.

Sulfation results 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 allowed to sit
unmaintained in storage self-discharge, sulfate
to various degrees, and lose capacity.
Repeated charging will generally result in the
recovery of most of the battery's capacity,
though some permanent loss can be expected.

5.

DO NOT EXCESSIVELY DISCHARGE THE
BATTERIES.  Excessive discharge can cause
polarity reversal of individual cells, resulting in

Summary of Contents for LESTRONIC II

Page 1: ...good performance and maximum cycle life CAUTION 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 overall battery pac...

Page 2: ... VOLTAGE IS APPROXIMATELY 650 VOLTS CAUTION ALWAYS UNPLUG THE ELECTRICAL PLUGS FROM THE AC OUTLET AND THE BATTERIES BEFORE ATTEMPTING ANY REPAIRS TO THE CHARGER WARNING DO NOT OPERATE THE CHARGER IF IT IS MALFUNCTIONING PERSONAL INJURY OR PROPERTY DAMAGE COULD RESULT The Lestronic II battery charger is a reliable automatic charger designed for long trouble free service If a malfunction should deve...

Page 3: ...nsformer does not hum and the ammeter still does not register with the Electronic Timer Kit bypassed a continuity check of the charger AC circuit is necessary Disconnect the power supply cord from its outlet and the DC output connector from the battery connector and with a suitable continuity tester check the circuit across the power supply cord prongs With the Electronic Timer Kit bypassed the CI...

Page 4: ...power supply cord from its outlet and the DC output connector from the battery connector and remove the charger cover 2 Disconnect the GREEN if included BLACK and RED wires of the Electronic Timer Kit Then remove the BLACK and WHITE leads of the power supply cord and both primary transformer coil leads from the Electronic Timer Kit terminal tabs The Kit can be removed by removing the three mountin...

Page 5: ... READS 30 AMPS FOR MORE THAN 30 MINUTES This high output condition is caused by misuse connecting the charger to an incorrect battery system which is lower than what is rated for the charger A common error is to install one or more of the batteries in a battery pack reverse polarity Using a suitable DC voltmeter test to be sure all batteries in a battery pack are correctly wired and also test the ...

Page 6: ...hen the batteries will not longer perform as required they should be replaced Part B Charger does not turn off New batteries with all good cells should rise to at least 2 5 volts per cell This will allow the finish charge rate to taper below 8 amperes As batteries age individual cells may weaken and these cells may not reach 2 5 volts This will result in finish charge rates greater than 8 amperes ...

Page 7: ...ead so the wires do not break DANGER HIGH VOLTAGE WITH THE CHARGER OPERATING THE CHARGER CAPACITOR VOLTAGE IS APPROXIMATELY 650 VOLTS AC USE EXTREME CAUTION WHEN WORKING NEAR THE CAPACITOR TERMINALS In order to apply AC power directly to the transformer primary coil the Electronic Timer Kit must be bypassed Refer to Section 1 Part A for bypass procedures With the Electronic Timer Kit bypassed and ...

Page 8: ...8 L2115S89 Transformer Coil Voltage Test 36 Volt Charger Without Capacitor Transformer Coil Voltage Test 36 Volt Charger With Capacitor TEST RESULTS FOR OTHER BATTERY VOLTAGE RANGES 12 VDC 27 33 VAC 24 VDC 54 66 VAC 48 VDC 110 130 VAC WIRING DIAGRAM L2115S90 ...

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