LESTRONIC II 48 VOLT AUTOMATIC BATTERY CHARGER
LESTRONIC II 48 VOLT AUTOMATIC
BATTERY CHARGER
MODEL 18720
AC Input:
DC Output:
Battery Specifications:
TYPE 48LC25-8ET
Specifications
100-125 or 200-250 Volts AC
16 or 8 amps, 50 Hertz, single-phase
48 Volts DC, 25 Amps, tapering to 8 Amps
For use with 48-volt, 24-cell, series connected, 180-350 amp-hour, liquid electrolyte
(wet) lead-acid batteries
PLEASE SAVE THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS
For correct operation of the equipment, it is important to read and be familiar
with this entire manual before installing and operating the charger.
DO NOT DISCARD THIS MANUAL AFTER READING.
LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS. IT MEANS: BECOME
ALERT—YOUR SAFETY IS INVOLVED.
IF YOU DO NOT FOLLOW THESE SAFETY
INSTRUCTIONS, INJURY OR PROPERTY DAMAGE CAN OCCUR.
IMPORTANT SAFETY INSTRUCTIONS
° Pins on plug of extension cord are the same
number, size, and shape as those of plug on
charger;
This manual contains important safety and operating
instructions. Before using battery charger, read all
instructions and cautionary markings on battery
charger, battery, and product using battery.
° Extension cord is properly wired and in good
electrical condition;
· Do not expose charger to rain or snow.
° Wire size is large enough for AC ampere rating
of charger.
· Use of an attachment not recommended or sold by
the battery charger manufacturer may result in a
risk of fire, electric shock, or injury to persons.
· Do not operate charger with damaged cord or plug;
replace it immediately.
· To reduce risk of damage to electrical plug and
cord, pull by plug rather than cord when
disconnecting charger.
· Do not operate charger if it has received a sharp
blow, been dropped, or otherwise damaged in any
way. Take it to a qualified service center.
· Make sure cord is located so that it will not be
stepped on, tripped over, or otherwise subjected to
damage or stress.
· Do not disassemble charger; take it to a qualified
service center when service or repair is required.
Incorrect reassembly may result in a risk of electric
shock or fire.
· When using an extension cord, make sure that:
Operating Instructions
1
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· To reduce risk of electric shock, unplug charger
from a live outlet or disconnect AC power to the
outlet before attempting any maintenance or
cleaning. Turning off controls will not reduce this
risk.
For 100-125 VAC: Connect transformer primary lead
#6 to timer kit terminal #3, AND transformer primary
lead #7 to timer kit terminal #2.
INTRODUCTION
GROUNDING INSTRUCTIONS
This battery charger is a self-regulating charger with a
minimum of moving parts, designed for long, troublefree service.
Built-in line voltage compen-sation
produces a consistent output when the AC supply
voltage varies by as much as 10% from nominal.
Convection cooling maximizes the reliability and
minimizes any maintenance costs. ONLY LIQUID
ELECTROLYTE (WET) LEAD ACID BATTERIES
should be recharged with this charger to ensure
superior battery performance and life. A patented
electronic circuit turns the charger on and off
automatically. When the battery has reached its
maximum state of charge, the circuitry will turn the
charger off.
This battery charger must be grounded to reduce the
risk of electric shock. This charger is equipped with
an AC supply cord having an equipment-grounding
conductor which must be connected to the ground
prong of an appropriate plug for the AC voltage being
used. This plug must be connected to an appropriate
AC outlet which is properly installed and grounded in
accordance with the National Electrical Code (U.S.)
and all local codes and ordinances.
For 200-250 VAC:
Connect BOTH transformer
primary leads #6 and #7 to timer terminal #6.
DANGER: IMPROPER CONNECTION OF THE
EQUIPMENT-GROUNDING
CONDUCTOR
CAN
RESULT IN A RISK OF ELECTRIC SHOCK.
The conductor with insulation having an outer surface
which is green, with or without yellow stripe(s), is the
equipment-grounding conductor.
If repair or
replacement of the AC supply cord or plug is
necessary, do not connect the equipment-grounding
conductor to a live terminal. Refer to a qualified
service agent.
RECEIVING AND INSTALLING THE CHARGER
When the charger is received, check for possible
in-transit damage. If any damage is found, it should
be reported as a claim to the carrier.
Proper installation of the charger is important in order
to achieve good charger 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 air flow for convection
cooling, allow three inches (3") minimum between the
charger and any wall.
EXTENSION CORD REQUIREMENTS
Always use a three-conductor, No. 14 AWG (1.5mm)
heavy duty cord with ground, properly wired, in good
electrical condition and keep it as short as possible.
Make sure the pins on the plug of the extension cord
are the same number, size and shape as the AC plug
of the battery charger. The use of an improper
extension cord could result in a risk of fire or electric
shock. Locate all cords so they will not be stepped
on, tripped over or otherwise subjected to damage or
stress.
DANGER: TO REDUCE THE RISK OF FIRE, DO
NOT USE THE CHARGER NEAR FLAMMABLE
MATERIALS OR VAPORS.
AC INPUT
CAUTION: TO REDUCE RISK OF ELECTRIC
SHOCK OR FIRE, DISCONNECT POWER FROM AC
RECEPTACLE BEFORE INSTALLING, CHANGING
AC VOLTAGE OR REMOVING UNIT.
DC OUTPUT
This battery charger is designed to produce a 48 volt
DC output with an initial charge current of 25 amps.
ONLY 48 VOLT, 24 CELL, SERIES CONNECTED,
180 TO 350 AMP-HOUR, LIQUID-ELECTROLYTE
(WET) LEAD-ACID BATTERIES SHOULD BE USED.
The charge current will decrease gradually to about 8
amps as the battery reaches full charge and will
remain there until the charger turns off. As the
battery ages, the charge current may no longer
decrease to the 8 amp finish current.
Liquid
electrolyte batteries will normally be charged to 2.52.6 volts per cell.
This battery charger can be adjusted to operate on
two different 50 Hertz, single phase AC line voltages.
Remove the cover to determine or change the internal
line voltage setting. Refer to wiring diagram at the
end of this manual.
NOTE: Transformer primary lead #5 remains
connected to timer kit terminal #2 and
transformer primary lead #8 remains
connected to timer kit terminal #3 for either
voltage setting.
Operating Instructions
2
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OPERATING INSTRUCTIONS
1.
2.
3.
GROUNDED. If any problems cannot be resolved,
consult a qualified service center.
Connect the DC output cable to the batteries.
The BLACK wire must be connected to battery
negative (-), and the RED or WHITE wire to
battery positive (+). Make sure all connections
are clean and tight.
Observe the following battery maintenance procedures
to obtain good performance and maximum cycle life.
1.
Connect AC supply cord to a properly grounded
100-125 or 200-250 VAC, 50 Hertz, single phase
outlet. Make sure the charger is set to operate
on the AC voltage being used. See AC INPUT
section of this manual.
The charger will start after a short delay as
indicated by the transformer hum.
WARNING:
LEAD
ACID
BATTERIES
GENERATE GASES WHICH CAN BE EXPLOSIVE.
CHARGE ONLY IN WELL VENTILATED AREAS.
DO NOT DISCONNECT CHARGER DC OUTPUT
TERMINALS FROM BATTERY WHEN CHARGER IS
ON. THE RESULTING ARCING AND BURNING
COULD CAUSE THE BATTERY TO EXPLODE.
KEEP
SPARKS,
FLAME,
AND
SMOKING
MATERIALS AWAY FROM BATTERY.
If the charger must be stopped, always
disconnect the AC supply cord from its outlet
before disconnecting the DC output terminals
from the battery.
4.
5.
6.
The initial charge current should range between
approximately 20 to 29 amps. If the batteries
have not been discharged, or the AC supply
voltage is lower than the nominal AC voltage
being used, the initial charge rate may be less. If
the batteries have been excessively discharged,
or AC supply voltage is higher than the nominal
AC voltage being used, the initial charge rate may
be more.
Charge current will gradually taper to
approximately 8 amps depending on the age and
condition of the batteries. Charger turns off
automatically when battery is fully charged.
Charge time varies with battery size and depth of
discharge.
Allow 11-15 hours for normal
charging. Severely discharged batteries may
require more time to be properly charged and
equalized.
a.
Someone should be within range of your voice
or close enough to come to your aid when
you work near a battery.
b.
Have plenty of fresh water and soap nearby in
case battery acid contacts skin, clothing or
eyes.
c.
Wear complete eye protection and clothing
protection.
Avoid touching eyes while
working near battery.
d.
If battery acid contacts skin or clothing, wash
immediately with soap and water. If acid
enters eye, immediately flood eye with
running cold water for at least 10 minutes and
get medical attention.
e.
NEVER smoke or allow a spark or flame in
the vicinity of batteries.
f.
Be extra cautious to reduce risk of dropping a
metal tool onto battery. It might spark or
short-circuit battery or other electrical part
that may cause explosion.
g.
Remove personal metal items such as rings,
bracelets, necklaces, and watches when
working with a lead acid battery. A lead acid
battery can produce a short-circuit current
high enough to weld a ring or the like to
metal, causing a severe burn.
h.
NEVER charge a frozen battery.
DANGER: TO REDUCE RISK OF ELECTRIC
SHOCK, ALWAYS DISCONNECT THE AC SUPPLY
CORD FROM ITS OUTLET AND THE DC OUTPUT
CORD
FROM
THE
BATTERY
BEFORE
ATTEMPTING ANY MAINTENANCE (CHANGING
FUSES, ETC.) OR CLEANING OF THE BATTERY
OR BATTERY CHARGER.
After the charger has turned off, disconnect the
AC supply cord from outlet.
2.
New batteries should be given a full charge before
their first use because it is difficult to know how
long batteries have been stored.
3.
Limit use of new batteries for first five cycles.
New batteries are not capable of their rated output
until they have been discharged a number of
times.
4.
Do not excessively discharge batteries.
Excessive discharge can cause polarity reversal
of individual cells resulting in complete failure
MAINTENANCE INSTRUCTIONS
The battery charger requires minimal maintenance. It
should be kept clean and all connections are to be
tightly secured. In the event of intermittent operation,
examine and tighten, if necessary, all connections.
BE SURE THE CHASSIS IS SECURELY
Operating Instructions
Always observe the following personal safety
precautions when working with lead acid
batteries:
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shortly thereafter. Limited use of new batteries
will minimize the chance of cell reversal.
5.
6.
3.
CHECK THE LEVEL OF THE ELECTROLYTE IN
CONVENTIONAL LIQUID ELECTROLYTE LEAD
ACID BATTERIES MONTHLY. MAIN-TAIN THE
PROPER ELECTROLYTE LEVEL BY ADDING
DISTILLED OR PURIFIED WATER WHEN
NECESSARY. Electrolyte levels lower during
discharge and rise during charge. Therefore, it is
mandatory that water be added to cells ONLY
when they are fully charged; do not overfill. Old
batteries require more frequent additions of water
than new batteries.
4.
Keep tops of batteries clean and dry to prevent
excessive self-discharge. Keep battery terminals
reasonably tight.
TROUBLESHOOTING GUIDE
For safe and efficient troubleshooting, read this
guide completely before beginning any tests.
CAUTION: DO NOT OPERATE THE CHARGER
IF IT IS DAMAGED OR APPEARS TO BE
MALFUNCTIONING.
PERSONAL INJURY OR
DAMAGE TO THE CHARGER OR BATTERIES MAY
RESULT. DO NOT DISASSEMBLE THE CHARGER.
TAKE IT TO A QUALIFIED SERVICE AGENT WHEN
SERVICE OR REPAIR IS REQUIRED. INCORRECT
REASSEMBLY MAY RESULT IN RISK OF
ELECTRIC SHOCK OR FIRE.
5.
6.
7.
Charger does not turn on
a.
Battery is not connected to charger.
b.
Charger is not plugged into a live AC outlet.
c.
DC fuses blown.
WARNING: IF THE AC OR DC PLUG OR
RECEPTACLE IS BROKEN, TWISTED, BENT OR
LOOSE
AND
DOES
NOT
MAKE
GOOD
ELECTRICAL CONTACT, HAVE IT REPLACED BY
QUALIFIED SERVICE PERSONNEL IMMEDIATELY.
DO NOT USE THIS CHARGER IN THIS CONDITION
AS FIRE OR PERSONAL INJURY CAN RESULT.
2.
a.
The DC cord was accidentally disconnected
from the battery during charge.
b.
The battery has been allowed to sulfate.
Charge the battery at least once every three
days when the equipment is lightly utilized.
Once sulfation is allowed to take place, it
may be partially reduced by returning,
temporarily, to daily charging.
c.
AC circuit is not live (power outage or circuit
breaker blown).
Charger does not turn off
a.
The charger is connected to a battery with an
amp-hour capacity greater than specified.
b.
The charger is connected to a battery pack
with a system voltage higher or lower than
specified.
c.
New batteries (5 cycles or less), cold
batteries or over-discharged batteries may
require an extended charge time to achieve
full charge.
Charger fuse blows (or circuit breaker)
a.
To determine if a charger malfunction exists, eliminate
the problems not associated with the charger in the
sections below. If the problem can not be resolved,
contact a qualified service center.
1.
Charger turns off early
Building AC line circuit breaker or fuse blows
a.
A "weak" fuse or circuit breaker is protecting
the circuit. Connect the charger to another
outlet on a different circuit. If the charger
operates properly, have a qualified electrician
inspect and test the original circuit.
b.
The circuit is overloaded.
Connect the
charger to another outlet on a different circuit.
Equipment range decreasing
a.
The electrolyte level in conventional liquid
electrolyte lead-acid batteries was allowed to
drop below the top of the battery plates. Add
distilled water to just cover the tops of the
plates immediately upon discovery and fill to
the proper level with distilled water at the
completion of the very next charge cycle.
Battery capacity lost in this manner is
permanent and is not recovered with
additional charge cycles.
b.
Use of the equipment before the batteries
have been fully charged and the charger turns
off. This shortens battery life and hastens the
onset of reduced daily range.
Battery
capacity lost in this manner is permanent and
is not recovered with additional charge
cycles.
c.
This is the normal wearout process for all
types of deep-cycle motive power batteries.
Charger remains at high rate
a.
The charger is connected to a battery pack
with a system voltage lower than specified.
b.
Battery amp-hour capacity is greater than
specified for charger.
c.
One or more of the batteries in the battery
pack has reversed polarity.
Operating Instructions
4
AC fuse blows when wrong AC power supply
is used.
01623H
WIRING DIAGRAM
PARTS LIST FOR LESTRONIC II CHARGER
MODEL 18720 TYPE 48LC25-8ET
100-125 OR 200-250 VAC / 50 HZ
PART NO.
24614S
24684S
16354S
16369S
14930S
02390S
08776S
02028S
02008S
24364S
25787S
30764S
25788S
24436S
27652S
25786S
24358S
30763S
Operating Instructions
QTY.
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
DESCRIPTION
CASE ASSEMBLY
TRANSFORMER ASSEMBLY
HEATSINK ASSEMBLY, W/ DIODES
AMMETER
ELECTRONIC TIMER ASSEMBLY
CAPACITOR, 6.0 MFD, 660 VAC
FUSE ASSEMBLY
BUSHING, 7W-2, INSULATOR FOR AC CORD
BUSHING, 8P-2, INSULATOR FOR DC CORD / AMMETER CORD
CORDSET, AC, 14/3, 46"
CORDSET, AC, 14/3, 94"
CORDSET, AC, 14/3, 40”
CORDSET, DC, 10/2, 3/8 RINGS, 54"
CORDSET, DC, 10/2, 3/8 RINGS, 74"
CORDSET, DC, 10/2, 3/8 RINGS, 85"
CABLE, REMOTE AMMETER, 10/2, 92"
CABLE, REMOTE AMMETER, 10/2, 26"
CABLE, REMOTE AMMETER, 10/2, 36”
5
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LIMITED
WARRANTY
Lester Electrical warrants each new Lester Battery Charger for defects in material and workmanship for a period of two
(2) years from the date of manufacture of the complete unit. Repairs can be made at the Lester factory. To do so, first
obtain a "Return Material Authorization" number by calling the Service Department of Lester Electrical (402 477-8988) or by
e-mailing service@lesterelectrical.com and send the defective unit with transportation charges prepaid to:
Lester Electrical
625 West A Street
Lincoln, NE 68522-1794 USA
Attention: Service Department
RMA #
For repairs made at other than the Lester factory, Lester will provide only the replacement parts. Defective parts should
be sent with transportation charges prepaid to the Lester factory at the address noted above.
If the unit or parts are found in the reasonable judgment of Lester to be defective in material or workmanship, repair or
replacement will be made by Lester without charge for parts or labor. Repair or replacement will be at the discretion of
Lester, with replacements being made using current models or parts performing the equivalent function. Labor charges
other than those incurred at the Lester factory are not covered under this warranty. All expenses associated with delivering
defective items to the Lester factory and the expense of returning repaired or replaced items from the Lester factory to 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 and
ammeters, is limited to the period specified in the original manufacturer's warranty.
This warranty does not cover any charger that has been subject to misuse, neglect, negligence, or accident, or operated
in any way contrary to instructions specified on the charger case and in the owner's manual. No claim of breach of warranty
shall be cause for cancellation of the contract of sale of any Lester charger. Lester assumes no responsibility for loss of
time, inconvenience, or other damage, consequential or otherwise, resulting from a defective charger. All implied
warranties (including merchantability) are limited in duration to the two years from date of manufacture warranty period.
Some states do not allow the exclusion or limitation of incidental or consequential damages; or limitations on how long
an implied warranty lasts, so the above limitations may not apply to you. This warranty gives you specific legal rights, and
you may also have other rights which vary from state to state.
Lester's obligation under this warranty is strictly and exclusively limited to the repair or replacement of defective items.
Lester issues this warranty in good faith and with full confidence in the workmanship and quality of Lester products.
Operating Instructions
6
01623H
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