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35827_A

COMPONENT REPLACEMENT PROCEDURES

To be able to use the component replacement procedures safely and effectively, it is important
to read this guide completely before beginning any tests.

CAUTION: REPAIRS BY QUALIFIED PERSONNEL ONLY. NOTE – MODIFYING THIS

CHARGER FOR USE OTHER THAN THAT FOR WHICH IT WAS INTENDED, REPAIRS BY
PERSONS NOT QUALIFIED, OR NOT USING ORIGINAL EQUIPMENT REPLACEMENT
PARTS WILL VOID THE WARRENTY AND LESTER LIABILITY.

DANGER: HIGH VOLTAGE! WITH THE CHARGER ON, THE INTERNAL CHARGER

CAPACITOR VOLTAGE IS APPROXIMATELY 660 VOLTS.

CAUTION: ALWAYS UNPLUG THE AC AND DC CORDS 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.

This battery charger is a reliable, automatic charger designed for long, trouble-free service. To
install a replacement, identify the item and follow its replacement procedures.

SECTION

COMPONENT REPLACEMENT PROCEDURES

13

ELECTRONIC CHARGE CONTROLLER REPLACEMENT

14

DIODE ASSEMBLY REPLACEMENT

15

CAPACITOR REPLACEMENT

16

AC INPUT AND DC OUTPUT CORD REPLACEMENT

17

FUSE ASSEMBLY REPLACEMENT

13.

ELECTRONIC CHARGE CONTROLLER REPLACEMENT

No soldering and only a Phillips screwdriver is required. To replace the kit, follow the step-by-
step procedures listed below.

DANGER: HAZARD OF ELECTRICAL SHOCK. DO NOT ATTEMPT TO SERVICE YOUR

CHARGER WHILE IT IS CONNECTED TO AN AC INPUT OUTLET OR TO THE BATTERY
RECEPTACLE. TURNING OFF THE CHARGER DOES NOT REDUCE THIS RISK!

1. Disconnect the charger’s AC input cord from its outlet and the DC output plug from the

battery receptacle.

2. Remove the Phillips screws that retain the cover and then remove the cover.

3. Disconnect the BLACK and RED wire connector from the existing electronic charge

controller. Remove the BLACK and WHITE leads of the AC input cord and both primary
transformer coil leads from the terminal tabs on the existing electronic charge controller.
The old controller can now be removed by removing the two mounting screws on the
charger front panel.

4. Align the two dimpled mounting guide locations on the bottom of the new charge controller

(as shown in Figure 13A) with the two hole-mounting pattern on the charger enclosure. Drive

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Содержание 19300

Страница 1: ...OF MOTIVE POWER BATTERIES 2 TROUBLESHOOTING GUIDE 3 1 CHARGER DOES NOT TURN ON 4 2 CHARGER FUSE BLOWS 5 3 AMMETER READS 25 AMPS FOR MORE THAN 30 MINUTES 6 4 CHARGER OUTPUT IS LOW 6 5 CHARGER TURN OFF MALFUNCTIONS 6 6 AC LINE FUSE OR CIRCUIT BREAKER BLOWS 8 COMPONENT TEST PROCEDURES 9 7 ELECTRONIC CHARGE CONTROLLER TESTING 9 8 TRANSFORMER TESTING 12 9 DIODE ASSEMBLY TESTING 14 10 CAPACITOR TESTING ...

Страница 2: ...cause permanent cell damage resulting in reduced energy capacity and shortened life 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 by adding water when necessary Distilled or de ionized water is free of contaminants and preferred for this use Ne...

Страница 3: ... WARNING DO NOT OPERATE THE CHARGER IF IT IS MALFUNCTIONING PERSONAL INJURY OR PROPERTY DAMAGE COULD RESULT This battery charger is a reliable automatic charger designed for long trouble free service If a malfunction should develop identify the symptom and follow the associated test procedures SECTION MALFUNCTION SYMPTOM 1 CHARGER DOES NOT TURN ON 1A Relay does not close no transformer hum and amm...

Страница 4: ...NING IF THE PLUG OR RECEPTACLE IS BROKEN TWISTED BENT OR LOOSE AND DOES NOT MAKE GOOD ELECTRICAL CONTACT HAVE IT REPLACED BY A QUALIFIED SERVICE AGENT IMMEDIATELY DO NOT USE THE CHARGER IN THIS CONDITION AS FIRE OR PERSONAL INJURY CAN RESULT Disconnect the AC input cord from its outlet and the DC output plug from its receptacle Measure the DC voltage at the battery and at the battery receptacle us...

Страница 5: ...o NOT attempt to repair the fuse link as inadequate protection will result 2A Single fuse link blows This condition is normally caused by a short circuit failure of one diode The fuse link will blow when the charger DC output plug is connected to the battery receptacle regardless of whether the AC input cord is connected to an outlet To check the diodes refer to Diode Assembly Testing SECTION 9 2B...

Страница 6: ...s which might cause the output to be low are the following Short circuit failure of a transformer coil Loose wiring connection in the charging circuit Capacitor problem Open diode Refer to Component Test Procedure section to check each of these potential issues CAUTION DO NOT USE THE CHARGER IF THE OUTPUT IS LOW BATTERIES WILL NOT REACH FULL CHARGE THEREBY INCREASING THE POSSIBILITY OF BATTERY DAM...

Страница 7: ... charger is working properly if after several charge cycles the battery capacity increases to near normal Sulfation occurs most often when the batteries have been stored without weekly charging New batteries may also be sulfated due to extended shipment or storage time prior to sale As batteries age individual cells may weaken causing a reduction in battery capacity This condition normally results...

Страница 8: ...etween the test clock time and the actual time Charge time on new batteries will generally run longer as the internal chemistry of the battery continues to change during its break in period of about 20 cycles During this period heavy gassing from the battery is normal 6 AC LINE FUSE OR CIRCUIT BREAKER BLOWS If this occurs when the charger AC input cord is connected to an outlet without the DC outp...

Страница 9: ...he associated test procedures SECTION COMPONENT TESTING PROCEDURES 7 ELECTRONIC CHARGE CONTROLLER TESTING 7A Relay Not Closing 7B Not Turing Off 8 TRANSFORMER TESTING 9 DIODE ASSEMBLY TESTING 10 CAPACITOR TESTING 11 AC INPUT CIRCUIT TESTING 12 DC OUTPUT CIRCUIT TESTING 7 ELECTRONIC CHARGE CONTROLLER TESTING The electronic charge controller is used to start and stop each charge cycle It is designed...

Страница 10: ... screws holding the relay board assembly to the potted electronic board are tight A loose connection on these screws will prevent the charger from starting With the multi meter adjusted to measure 120 volts AC place the test probes across points A top screw head and C bottom screw head as shown in Figure 7C If input line voltage is not present after the five second delay time the electronics have ...

Страница 11: ... charge controller is defective and must be replaced CAUTION DO NOT CHARGE BATTERIES WITH THE ELECTRONIC CHARGE CON TROLLER BYPASSED THE CHARGER WILL REMAIN ON AS LONG AS THE AC INPUT CORD IS CONNECTED TO A LIVE OUTLET SEVERE OVERCHARGING AND EVENTUAL DAMAGE TO BATTERIES WILL RESULT 7B Not Turning Off The electronic charge controller has a built in maximum timer which will turn the charger off if ...

Страница 12: ...mally After the charge output amperage has tapered to its lowest point measure the battery terminal voltage using a DC voltmeter capable of reading in increments of 001 volts Continue charging and check the battery voltage reading every hour If the battery voltage increases less than 072 volts or if the battery voltage decreases between successive hourly readings the charger should turn off If the...

Страница 13: ...sure its output Bypass the electronic charge controller as described in SECTION 7A Figure 7E verifying that the terminals are making electrically sound connections Attach the clips of the meter to the transformer output leads as shown in Figure 8 Adjust your meter to measure the maximum AC voltage anticipated from the transformer 97 volts For your personal safety insure that the meter clips touch ...

Страница 14: ...o its highest DC voltage scale and then touch and hold the test leads to the capacitor terminals for three seconds Follow this by shorting across the terminals with an insulated metal tool A capacitor discharged in this manner will be safe to touch Carefully remove one of the quick disconnect female terminals from the capacitor Use a large needle nose pliers or similar clamping tool that you feel ...

Страница 15: ...larity attach the red positive lead to the upper diode and attach the black negative lead to the center DC output terminal Set your meter to the diode check position as shown in Figure 9B Figure 9A Figure 9B The value you see should vary between 450 and 600 volts DC due to the variations in diodes and test meters If this diode had failed shorted the meter would display 000 or sound an audible beep...

Страница 16: ...ut terminal is common to both tests and the meter settings remain the same The same conditions for shorted and open diodes described in the first test still apply Service tips A continuity light is a very good alternative test device to test a diode It has a light bulb a battery a needle like probe on the body and a short wire lead with an alligator clip on it If you do not feel confident when usi...

Страница 17: ...CITOR TERMINALS CAN BE AS HIGH AS 660 VOLTS WHILE THE CHARGER OPERATES USE EXTREME CAUTION WHEN NEAR THE CAPACITOR TERMINALS WARNING THE CAPACITOR STORES AN ELECTRICAL CHARGE AND MAY NOT BE FULLY DISCHARGED TO AVOID AN ELECTRICAL SHOCK FROM THE CAPACITOR YOU MUST DISCHARGE IT COMPLETELY Figure 10A Discharge the capacitor by adjusting your test meter to its highest DC voltage scale and then touch a...

Страница 18: ... its limit This is why this capacitor measured 3 000 If you thought it had failed open you would have guessed wrong because the meter exceeded its limit just before the picture for Figure 10A was taken The reason why the resistance value increases is that the battery of the test meter charges the capacitor and the meter indicates this increased charge Unlike an instrument quality meter this consum...

Страница 19: ...AC input cord transformer primary coil wires and the electronic charge controller If the charger is wired correctly individually check the continuity of the AC input cord transformer primary and relay to see if any of these have failed open If the AC wall breaker blows there may be a short in the AC circuit Disconnect the AC input cord from its outlet and the DC output plug from the battery recept...

Страница 20: ...lete in only one direction If the circuit does not conduct in either direction and the DC output fuse is good individually check the continuity of the DC output cord ammeter diodes and all connections If the circuit conducts in both directions a short exists in the charger DC circuit First check the DC output cord for a short between the two wires It is more likely that one or both diodes have sho...

Страница 21: ...RGE CONTROLLER REPLACEMENT 14 DIODE ASSEMBLY REPLACEMENT 15 CAPACITOR REPLACEMENT 16 AC INPUT AND DC OUTPUT CORD REPLACEMENT 17 FUSE ASSEMBLY REPLACEMENT 13 ELECTRONIC CHARGE CONTROLLER REPLACEMENT No soldering and only a Phillips screwdriver is required To replace the kit follow the step by step procedures listed below DANGER HAZARD OF ELECTRICAL SHOCK DO NOT ATTEMPT TO SERVICE YOUR CHARGER WHILE...

Страница 22: ...ctronics 5 Attach the wire connector to the new electronic charge controller as shown in Figure 13B If a new BLACK and RED wire harness needs to be installed connect the RED wire from the electronic charge controller to the same point as the WHITE positive DC lead on the diode assembly The BLACK wire connects to the RED sense lead on the DC output cord or to the same point as the BLACK negative DC...

Страница 23: ... and the DC output plug is connected to the battery receptacle b When the last of the two connections are made either AC or DC after a short delay 3 5 seconds the control relay will click the transformer will hum and the ammeter will indicate charge current c If your charger performs as above it is ready for use if not refer to the wiring diagram and check to be sure the charger is wired correctly...

Страница 24: ...enclosure and fasten the heatsink to the base through the holes where the old heatsink was mounted Insert the mounting screws from the outside of the enclosure through the plastic body of the assembly then install the two flat washers on the mounting screw and torque the nylon lock nuts to a maximum of 22 inch pounds 6 Attach the RED wire from the electronic charge controller and the WHITE DC outp...

Страница 25: ...LY 3 Discharge the capacitor by adjusting your multi meter to its highest DC voltage scale and then touch and hold the test leads to the capacitor terminals for three seconds Follow this by shorting across the terminals with an insulated metal tool A capacitor discharged in this manner will be safe to touch 4 Carefully remove both of the quick disconnect female terminals Use a large needle nose pl...

Страница 26: ... strength will meet safety requirements 4 Use a flat bladed screwdriver to pry two of the strain relief mounting ears up Pry up the top one and the one closest to the enclosure side as shown in Figure 16A 5 Using a cutting tooling as shown in Figure 16B cut off the two mounting ears pried up in the previous step 6 Pull and wiggle the cord to remove the strain relief from the enclosure and remove t...

Страница 27: ...put plug from the battery receptacle 2 Remove the Phillips screws that retain the charger cover and then remove the cover 3 Remove the three nuts on the back of the fuse assembly which secure the two transformer secondary wires and the buss bar as shown in Figure 17 4 Loosen the nut that holds the buss bar to the ammeter and then remove the buss bar and the two wires from the fuse assembly 5 Remov...

Страница 28: ...www lesterelectrical com 28 35827_A CHARGER WIRING DIAGRAM ...

Страница 29: ... 216 POWER WISE PLUG OPTION 78 6 07755 15S 1 DC CORDSET 12 2 108 SB50 GRAY OPTION 03 6 36174 13S 1 DC CORDSET 12 2 108 SILICONE RUBBER PLUG OPTION 01 6 36182 13S 1 DC CORDSET 12 2 108 LESTER PLUG OPTION 02 6 07785 14S 1 DC CORDSET 12 2 108 SB 175 GRAY OPTION 04 7 35446 08S 1 AC CORDSET 16 3 97 W BUSHING NEMA 5 15P 8 16369S 1 AMMETER 30 AMP 9 04142S 1 CAPACITOR 3 MFD 660 VAC OPTION 88 S N 030605059...

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