Lester SUMMIT 27790, SUMMIT 27800, SUMMIT 28110, SUMMIT 28120, SUMMIT 27950 User Manual

Important Safety,
Installation,
Operation, and
Maintenance
Instructions

www.LesterElectrical.com

SWITCH MODE
INDUSTRIAL BATTERY CHARGER

USER’S MANUAL

SAVE THIS MANUAL: Keep it in a location where it is available to anyone who may

operate the charger.

CHARGER RATINGS LABEL

The ratings label is located on the back of the charger. The label provides the model (MODEL), part number
(PART NO), serial number (SERIAL NO), AC input ratings (INPUT), and DC output ratings (OUTPUT, CELLS,
and AH) of the charger. The amp-hour (AH) rating indicates the full range of battery capacities that are
recommended for use with this charger. Different battery profiles may be required to optimize the charging of
specific battery capacities within this range. The BATTERY field indicates the factory-configured battery profile.

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 or tag attached to your charger.

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part
15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This equipment generates, uses and can radiate
radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause
harmful interference in which case the user will be required to correct the interference at his own expense.

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TABLE OF CONTENTS

CHARGER RATINGS LABEL ................................................................................................... 2

TABLE OF CONTENTS ............................................................................................................. 2

IMPORTANT SAFETY INSTRUCTIONS ................................................................................... 4

1. INTRODUCTION ................................................................................................................... 6

2. RECEIVING AND INSTALLING THE CHARGER................................................................. 6

3. BATTERY TYPE ................................................................................................................... 8

4. OFF-BOARD (SHELF) VERSUS ON-BOARD (BUILT-IN) CHARGERS .............................. 9

4.1 Off-Board Chargers ................................................................................................... 9

4.2 On-Board Chargers ................................................................................................... 9

5. AC INPUT .............................................................................................................................. 9

6 DC OUTPUT ......................................................................................................................... 10

7 VEHICLE LOCKOUT CONTROL (OPTIONAL) ................................................................... 10

8 BATTERY TEMPERATURE SENSOR (OPTIONAL)........................................................... 11

9. PROPER CARE OF DEEP-CYCLE LEAD-ACID MOTIVE POWER BATTERIES ............. 11

9.1 Personal Safety Precautions .................................................................................. 12

10. CHARGER OPERATION .................................................................................................. 12

10.1 Off-Board Charger Operation ................................ ............................................... 13

10.2 On-Board Charger Operation ............................................................................... 14

10.3 Storage Mode Operation ....................................................................................... 14

11. LED INDICATORS ................................................................ ................................ ............ 15

12. FAULTS ............................................................................................................................ 16

13. TROUBLESHOOTING ...................................................................................................... 17

14. SPECIFICATIONS............................................................................................................. 18

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LOOK FOR THIS SYMBOL TO POINT OUT SAFETY PRECAUTIONS.
IT MEANS: BE ALERT—YOUR SAFETY IS INVOLVED. IF YOU DO
NOT FOLLOW THESE SAFETY INSTRUCTIONS, INJURY OR
PROPERTY DAMAGE CAN OCCUR.

IMPORTANT SAFETY INSTRUCTIONS

1. SAVE THESE INSTRUCTIONS – This manual contains important safety and operating instructions.

2. Before using battery charger, read all instructions and cautionary markings on battery charger,
battery, and product using battery.

3. DANGER: TO REDUCE THE RISK OF FIRE OR ELECTRIC SHOCK, CAREFULLY READ AND
FOLLOW THESE IMPORTANT SAFETY AND OPERATING INSTRUCTIONS BEFORE INSTALLING
OR OPERATING THE CHARGER.

4. INSTRUCTIONS IMPORTANTES CONCERNANT LA SECURITÉ.

5. WARNING: TO REDUCE THE RISK OF FIRE, INSTALL THIS BATTERY CHARGER ON A
SURFACE OF NON-COMBUSTIBLE MATERIAL SUCH AS BRICK, CONCRETE, OR METAL.

6. DANGER: RISK OF ELECTRIC SHOCK. DISCONNECT CHARGER FROM BATTERY AND AC
POWER BEFORE SERVICING. TURNING OFF 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 BATTERIES OF THE SAME TYPE, VOLTAGE, CELL NUMBER, AND
AMP-HOUR CAPACITIES AS SHOWN ON THE LABEL. OTHER TYPES OF BATTERIES MAY
BURST CAUSING PERSONAL INJURY AND DAMAGE. BEFORE CHARGING ANY OTHER TYPE OF
RECHARGEABLE BATTERY, CHANGE THE CHARGER SETTINGS AS RECOMMENDED BY THAT
BATTERY MANUFACTURER.

10. ATTENTION: UTILISER POUR CHARGER UNIQUEMENT LES ACCUMULATEURS AU PLOMB À

ELECTROLYTE LIQUIDE. D’AUTRES TYPES D’ACCUMULATEURS POURRAIENT ÉCLATER ET

CAUSER DES.

11. DANGER: TO PREVENT ELECTRICAL SHOCK, DO NOT TOUCH EITHER AC OR DC
UNINSULATED PARTS. MAKE SURE ALL ELECTRICAL CONNECTORS ARE IN GOOD WORKING
CONDITION. DO NOT USE CONNECTORS THAT ARE CRACKED, CORRODED OR DO NOT MAKE
ADEQUATE ELECTRICAL CONTACT. USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY
RESULT IN A RISK OF OVERHEATING OR ELECTRIC SHOCK.

12. WARNING: HAZARD OF ELECTRIC SHOCK.

13. WARNING: LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. TO PREVENT ARCING
OR BURNING NEAR BATTERIES, DO NOT DISCONNECT DC CHARGING CORD FROM BATTERIES

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WHEN THE CHARGER IS OPERATING. KEEP SPARKS, FLAME, AND SMOKING MATERIALS
AWAY FROM BATTERIES.

14. WARNING: ALWAYS SHIELD EYES WHEN WORKING NEAR BATTERIES. DO NOT PUT
WRENCHES OR OTHER METAL OBJECTS ACROSS BATTERY TERMINAL OR BATTERY TOP.
ARCING OR EXPLOSION OF THE BATTERY CAN RESULT.

15. WARNING: BATTERIES PRODUCE HYDROGEN GAS, WHICH CAN EXPLODE IF IGNITED.
NEVER SMOKE, USE AN OPEN FLAME, OR CREATE SPARKS NEAR THE BATTERY. VENTILATE
THE AREA WHEN THE BATTERY IS CHARGING IN AN ENCLOSED PLACE.

16. WARNING: LE AD-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.

17. WARNING: ONLY A QUALIFIED SERVICE TECHNICIAN SHOULD PROGRAM OR SERVICE
THIS EQUIPMENT.

18. CAUTION: DO NOT OPERATE THE CHARGER IF IT HAS RECEIVED A SHARP BLOW, BEEN
DROPPED, OR OTHERWISE DAMAGED. HAVE A QUALIFIED SERVICE TECHNICIAN EXAMINE
AND REPAIR AS NEEDED.

19. WARNING: DO NOT DISASSEMBLE THE CHARGER. HAVE THE CHARGER EXAMINED BY A
QUALIFIED SERVICE TECHNICIAN. INCORRECT RE-ASSEMBLY OF THE CHARGER MAY
RESULT IN AN EXPLOSION, ELECTRIC SHOCK, OR FIRE.

20. CAUTION: MAKE SURE THE BATTERY SYSTEM HAS THE PROPERLY RATED VOLTAGE,
AMP-HOURS, AND TYPE (“WET”, “AGM”, “GEL”, ETC.) FOR THIS CHARGING SYSTEM.

SAVE THESE INSTRUCTIONS

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1. INTRODUCTION

This switch mode (high frequency) industrial battery charger features advanced charge and termination
algorithms designed to optimize both daily battery capacity and overall battery life. The charger is convection
cooled with no moving parts, sealed, and designed to provide maximum reliability. The universal AC input
enables the charger to be used with a wide range of AC voltages and frequencies, and the charger includes
high efficiency and power factor.

The charger was factory-configured with a battery profile intended for use with batteries of the same type,
voltage, and number of cells as is listed on the ratings label (see the Charger Ratings Label section for
additional details). The charger was also factory-configured for on-board or off-board use. Contact your
dealer if you require a different configuration.

2. RECEIVING AND INSTALLING THE CHARGER

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.

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

IMMEDIATELY.

Unpack the charger and examine it for shipping damage. In the event that shipping damage is found, report it
as a claim with the freight company.

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 way. Contact your dealer.

Proper installation is important to achieve optimum performance and life from the charger and batteries.
Allow as much free air space around the charger as possible. Please refer to the Specifications section for
specific storage and operating environmental specifications.

The charger was factory-configured for mounting on-board a battery-powered vehicle/machine or off-board
use in a shelf or portable application. Contact your dealer if you desire to use the charger in a non-factory­configured manner.

The most favorable orientations of the charger are shown in Figure 2-1.
For on-board use, the most favorable way to mount the charger is with the charger base bolted to a metal

plate (0.1 inch minimum). This provides both a strong structural mounting and good thermal conductive
cooling (examples are shown in Figure 2-1, Views A and B). A poor thermal conductive mounting material
such as plastic or wood would be less favorable for cooling.

The charger dimensions and mounting slot locations are shown in Figure 2-2. For off-board use, optional
handles are available for ease in carrying.

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