Lester Electrical 26900, 27000, 27010, 27020, 27030 User Manual

Important Safety,
Installation,
Operation, and
Maintenance
Instructions

www.LesterElectrical.com

USER’S MANUAL

Industrial Battery Charger

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), serial number
(SERIAL NO.), AC input configuration (AC VOLTS, AC AMPS, PHASE and HERTZ) and DC output specifications
(CELLS, DC VOLTS, DC AMPS and AMP-HRS) of the charger. TYPE indicates the factory-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 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.

X-Series 2 of 20 User’s Manual

TABLE OF CONTENTS

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

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

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

2. RECEIVING THE CHARGER ................................................................................................ 6

3. STORAGE ............................................................................................................................. 6

4. BATTERY TYPE ................................................................................................................... 6

5. OFF-BOARD (SHELF) VERSUS ON-BOARD (BUILT-IN) CHARGERS .............................. 7

5.1 Off-Board Chargers .................................................................................................. 8

5.2 On-Board Chargers .................................................................................................. 8

6. LOCATION AND INSTALLATION ........................................................................................ 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 Inspections ................................................................................................. 16

12.3 Battery Conditions ................................................................................................ 16

13. TROUBLESHOOTING AND SERVICE ............................................................................. 17

X-Series 3 of 20 User’s Manual

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 LEAD-ACID BATTERIES. 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. CAUTION: DO NOT EXPOSE TO RAIN. INDOOR USE ONLY.

12. ATTENTION: NE PAS EXPOSER À LA PLUIE.

13. 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.

X-Series 4 of 20 User’s Manual

14. WARNING: HAZARD OF ELECTRIC SHOCK.

15. WARNING: LEAD-ACID BATTERIES GENERATE EXPLOSIVE GASES. TO PREVENT ARCING
OR BURNING NEAR BATTERIES, DO NOT DISCONNECT DC CHARGING CORD FROM BATTERIES
WHEN THE CHARGER IS OPERATING. PUSH THE “STOP/START” BUTTON TO TURN CHARGER
OFF. KEEP SPARKS, FLAME, AND SMOKING MATERIALS AWAY FROM BATTERIES.

16. 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.

17. 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.

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 CHARGER IF IT HAS RECEIVED A SHARP BLOW, BEEN
DROPPED, OR OTHERWISE DAMAGED. HAVE YOUR DEALER’S QUALIFIED SERVICE
TECHNICIAN EXAMINE AND REPAIR AS NEEDED.

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

22. 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

X-Series 5 of 20 User’s Manual

Model

Number

DC Output

Volts

DC Output

Amps

Amp-Hour Rating,

C20 Rate (12 Hrs)

AC Input

Amps

Shipping Weight,

Approx (Lbs)

26900 12 25 150 - 305 5 28
27020 12 50 250 - 510 9 35
27010 24 25 150 - 305 9.5 37
27030 24 35 190 - 395 12.5 42
27060 36 25 150 - 305 13.5 39
27050 36 30 170 - 350 14.5 45

27000 48 17 105 - 210 11.5 39

1. INTRODUCTION

This X-Series battery charger is an advanced, microprocessor-based, silicon-controlled rectifier (SCR) charger
designed to optimize both daily battery capacity and overall battery life. It plugs directly into standard 120V, 15A,
60 Hz AC outlets/receptacles for use in off-board (shelf) or on-board (built-in) applications. The charger is natural
convection cooled with no moving parts. It was factory-configured to charge wet, AGM, or gel deep-cycle, lead­acid batteries, and includes an internal jumper that can be used to select between two battery profiles in the field.
This charger features fully-automatic operation with a manual stop/start button, low battery voltage start button,
self diagnostic button, ammeter, and status LEDs.

Figure 1-1 provides specifications for the X-Series product line.

Figure 1-1: X-Series Product Line Specifications

2. RECEIVING THE CHARGER

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.

3. STORAGE

When the charger is stored 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 stack anything
on top of the charger.

4. BATTERY TYPE

WARNING: DISCONNECT BOTH AC AND DC POWER FROM THE CHARGER BEFORE OPENING THE
CASE. CONTACT WITH LIVE COMPONENTS WITHIN THE CHARGER COULD CAUSE ELECTRICAL
SHOCK, SERIOUS INJURY, OR DEATH.

This charger is designed to charge deep-cycle lead-acid batteries of wet/flooded, AGM (absorbed glass mat), or
gel design. The charger is factory-configured to charge the type of battery indicated in the TYPE field on the

charger ratings label (for example, “Wet”). Additionally, the charger includes a secondary battery profile available

via an internal jumper on the control board. The last four (4) characters in the charger part number, available in
the MODEL field on the charger ratings label, provide the battery profile codes for both the primary and secondary
battery profiles. For example, charger part number 27030C84F1S1W1A1 has a primary battery profile code of
“W1” and a secondary battery profile code of “A1”. Figure 4-1 lists standard battery profile codes and their
corresponding battery profiles. If a battery profile code for your charger is not listed in Figure 4-1, please contact
your dealer regarding which battery profiles are available on your charger.

X-Series 6 of 20 User’s Manual