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X-Series

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User’s Manual

13. TROUBLESHOOTING AND SERVICE

CAUTION: DO NOT DISASSEMBLE THE CHARGER. TAKE IT TO A QUALIFIED SERVICE TECHNICIAN

WHEN SERVICE OR REPAIR IS REQUIRED. INCORRECT REASSEMBLY MAY RESULT IN A RISK OF
ELECTRIC SHOCK OR FIRE.

DANGER: TO REDUCE THE RISK OF ELECTRIC SHOCK, ALWAYS DISCONNECT BOTH THE POWER

SUPPLY CORD AND THE OUTPUT CORD BEFORE ATTEMPTING ANY MAINTENANCE OR SERVICE.

WARNING: DO NOT OPERATE THE CHARGER IF IT IS MALFUNCTIONING. PERSONAL INJURY OR

PROPERTY DAMAGE COULD RESULT.

The charger was fully tested and calibrated before leaving the factory. It was delivered ready to charge. If
properly installed, the charger should require very little attention. If improper charger operation occurs, it will
require repair by a qualified service technician.

SERVICE PARTS LIST

#

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 26815-00S 26815-00S 26815-00S 26815-00S 26815-00S

5

AC

Circuit

Breaker

35363S 31847S 31847S 34882S 34882S 34882S 34882S

6

Ammeter

16369S 20726S 16369S 16823S 16369S 16823S 16895S

7

Misc Switch Kit
(Stop/Start, Low
Voltage, Self Diagnostic)

37446S 37446S 37446S 37446S 37446S 37446S 37446S

8 AC

Cordset

Kit

21307-08S 21307-08S 21307-08S 21307-08S 21307-08S 21307-08S 21307-08S

9

DC Cordset Kit

Contact Your Sales Representative

N/A

Misc Wiring Kit
(LEDs, Control Cables,
Misc Wires)

37441S 37442S 37441S 37441S 37441S 37441S 37441S

N/A

Optional Lockout Relay
Kit

37676S 37676S 37676S 37676S 37676S 37676S 37676S

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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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