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X-Series 

15 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 for 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.  If 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 

State 

“Charging” LED 

State 

Self Diagnostic 

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 battery) 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. 
 

 

Summary of Contents for X-Series

Page 1: ...USER S MANUAL Industrial Battery Charger Important Safety Installation Operation and Maintenance Instructions 37414 www LesterElectrical com ...

Page 2: ...y configured battery type and if the charger is configured for on board operation An example charger ratings label is provided below Please fill in the blank label that is provided below with the information from the ratings label on your charger for future reference Document any configuration or settings changes that are made by marking the ratings label on your charger or on an additional label ...

Page 3: ...N 8 6 1 On Board Mounting 9 7 AC INPUT 9 8 DC OUTPUT 10 8 1 ROUND MOLDED 3 PIN PLUG 10 8 2 DC OUTPUT FUSE 10 9 PROPER CARE OF DEEP CYCLE MOTIVE POWER BATTERIES 11 9 1 Personal Safety Precautions 11 10 CHARGER OPERATION 12 10 1 User Interface 14 10 2 Low Voltage Start 15 10 3 Self Diagnostic and Faults 15 11 LOCKOUT INTERLOCK RELAY OPTION 16 12 MAINTENANCE 16 12 1 Check Charger Area 16 12 2 Visual ...

Page 4: ...FF THE CHARGER DOES NOT REDUCE THIS RISK 7 DANGER RISK OF ELECTRIC SHOCK DO NOT TOUCH UNINSULATED PORTION OF AC OR DC CONNECTORS OR UNINSULATED BATTERY TERMINAL 8 DANGER RISQUE DE CHOCKS ÉLECTRIQUES NE PAS TOUCHER LES PARTIES NON ISOLÉES DU CONNECTEUR DE SORTI OU LES BORNES NON ISOLÉES DE L ACCUMULATEUR 9 CAUTION CHARGE ONLY LEAD ACID BATTERIES OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL I...

Page 5: ...TTERY IS CHARGING IN AN ENCLOSED PLACE 18 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 19 WARNING ONLY YOUR DEALER S QUALIFIED SERVICE TECHNICIANS SHOULD PROGRAM OR SERVICE THIS EQUIPMENT 20 CAUTION DO NOT OPERATE THE ...

Page 6: ...red 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 F 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 s...

Page 7: ...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 ...

Page 8: ...RIALS AND VAPORS DO NOT USE NEAR 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 an...

Page 9: ...d 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 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 not connect the equipment...

Page 10: ...monly 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 The 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 plu...

Page 11: ...tion 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 expected 7 Cold batteries require more time to fully charge When the temperature falls below 65 F th...

Page 12: ...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 WARNING 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 WARNING DO NOT DISCONNECT THE CHARGER DC O...

Page 13: ...e solid illumination of the Charge Status LED 7 Disconnect the charger DC output connector from the battery pack connector by grasping both connectors and pulling them straight apart 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 wher...

Page 14: ... also includes an AC input circuit breaker and DC output fuse 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 Start Manually starts a charge cycle for a battery with a voltage too low to automatically start See Section 9 2 for details Self Di...

Page 15: ...e technician and provide them with the self diagnostic result Self Diagnostic LED State Charging LED State Self Diagnostic 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 ...

Page 16: ... 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 Th...

Page 17: ... Service Part Description 26900 12V 25A 27020 12V 50A 27010 24V 25A 27030 24V 35A 27060 36V 25A 27050 36V 30A 27000 48V 17A 1 Fuse Assembly 08776S 08799S 08776S 08774S 08776S 08774S 08776S 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...

Page 18: ...X Series 18 of 20 User s Manual WIRING DIAGRAMS MODEL 27020 ONLY ...

Page 19: ...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 an...

Page 20: ...X Series 20 of 20 User s Manual Represented By 37414H 37414 ...

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