background image

 

 
X-Series 

8 of 20 

User’s Manual 

5.1  Off-Board Chargers 

 
Off-board chargers are designed to be used in 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 

 

WARNING:  DO NOT INSTALL THE CHARGER ON OR NEAR FLAMMABLE MATERIALS.  POSITION 

THE CHARGER ON A FOUNDATION OF STONE, BRICK, CONCRETE OR GROUNDED METAL. 

WARNING: CHARGERS CAN IGNITE FLAMMABLE MATERIALS 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 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. 
 

WARNING: REPLACE WORN, DAMAGED, OR CUT ELECTRICAL CORDS AND PLUGS IMMEDIATELY.  

 

WARNING: KEEP DRY; DO NOT EXPOSE TO RAIN OR SPRAY. FOR STORAGE, KEEP CHARGER IN A 

BUILDING. NE PAS EXPOSER A LA PLUIE. 

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 ...

Reviews: