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X-Series 

11 of 20 

User’s Manual 

9.  PROPER CARE OF 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. 
 

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 the overall battery pack is correct.  

Otherwise, 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.  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. 

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 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. 

6.  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 expected. 

7.  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. 

8.  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. 

9.  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. 

10.  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 vicinity 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. 
 

Содержание X-Series

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

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

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

Страница 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...

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

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