Lester 15510 User manual

Operating Instructions 101316H
LESTRONIC BATTERY CHARGER
MODEL 15510 TYPE 72EL40-10ET
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.
INITIAL INSTALLATION
WARNING: REMOVE FRONT PANEL TO
INSPECT CHARGER FOR CORRECT INPUT
VOLTAGE AND BATTERY TYPE SETTING.
CONNECT JUMPER TO 208 FOR MEASURED
VOLTAGE BETWEEN 192 TO 224 AND 240 FOR
225 TO 256. PERSONAL INJURY OR DAMAGE
WILL OCCUR IF SETTINGS ARE INCORRECT.
Do not operate this charger with damaged cords.
Do not operate this charger if it has received a sharp
blow, was dropped or otherwise damaged in any
manner; refer to a qualified service agent.
Provide adequate ventilation for the batteries and
charger. The convection-cooled design requires an
unobstructed flow of cooling air for proper operation.
WARNING: HAZARD OF EXPLOSIVE GAS
MIXTURE. DO NOT DISCONNECT THE OUTPUT
CHARGING CONNECTOR WHILE THE CHARGER
IS OPERATING. THE RESULTING ARCING AND
BURNING WILL DAMAGE THE CONNECTORS
AND MAY CAUSE THE BATTERY TO EXPLODE.
IF CONNECTORS MUST BE DISCONNECTED
BEFORE THE CHARGER AUTOMATICALLY
SHUTS OFF, FIRST TURN THE CHARGER OFF
BY MOVING THE MAIN CONTROL SWITCH TO
"OFF" OR DISCONNECTING THE POWER CORD.
WARNING: KEEP DRY; DO NOT EXPOSE TO
RAIN.
NORMAL OPERATION
The instructions printed on the front panel of the
charger are for daily reference.
1. With the charger DC output cord disconnected
from the batteries, connect the power supply
cord to a properly grounded outlet of proper
voltage and frequency as specified on charger
nameplate.
CAUTION: THIS CHARGER IS FOR USE
ONLY ON 72 VOLT, 36 CELL, SERIES
CONNECTED, 180-250 AMP-HR (18 HR. RATE),
2.35-2.50 VOLTS PER CELL MAXIMUM VOLTAGE
BATTERY SYSTEMS. THIS CHARGER IS FOR
USE ON LIQUID ELECTROLYTE LEAD ACID AND
GEL CELL OR SEALED "MAINTENANCE FREE"
BATTERIES. "BATTERY TYPE" SWITCH MUST
BE SET TO THE PROPER TYPE OF BATTERY TO
BE CHARGED. BATTERIES IMPROPERLY
MATCHED WITH CHARGER MAY BURST,
CAUSING PERSONAL INJURY AND DAMAGE TO
BATTERIES OR CHARGER.
2. With the control switch in the "AUTO" position,
the charger will start automatically after a short
delay if all connections and the battery voltage

Operating Instructions 201316H
test good. Move the switch to the "AUTO"
position if it is not already there.
3. Connect the charger DC output connector to the
battery connector. The charger will auto-
matically turn on two to five (2-5) seconds after
the DC output cord is connected.
Ammeter indicates when charger is operating.
Correct initial charge rate should be around 40
amps depending upon the condition and depth
of discharge of the batteries. Under normal
conditions, the charge rate will taper to 10 amps
at finish.
Total recharge time will vary depending on depth
of discharge. Under normal conditions,
recharge time will not exceed 14 hours.
DANGER: RISK OF ELECTRIC SHOCK! DO
NOT TOUCH UNINSULATED PORTIONS OF THE
OUTPUT CONNECTOR OR UNINSULATED
BATTERY TERMINALS.
CAUTION: IN THE UNLIKELY EVENT THAT
THE CHARGER DOES NOT TURN OFF
AUTOMATICALLY, OVERCHARGING AND
POSSIBLE BATTERY DAMAGE MAY RESULT.
FOR BEST BATTERY LIFE, CHECK TO BE SURE
THE CHARGER HAS TURNED OFF PROPERLY
AFTER EACH CHARGE CYCLE.
STORAGE
When the machine is not in use, charge the batteries
once each week.
PROPER CARE OF 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 overall battery pack
is correct. Due to the electrical characteristics of
this charger, it is possible to improperly hook up
the batteries and not blow the fuse when
charging. 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. Limit the use of new batteries for the first five
cycles. New batteries are not capable of their
rated output until they have been discharged
and charged a number of times.
4. Do not excessively discharge the batteries.
Excessive discharge can cause polarity reversal
of individual cells resulting in complete failure
shortly thereafter. Limited use of new batteries
will minimize the risk of cell reversals.
5. Maintain the proper electrolyte level by adding
water when necessary. Never allow the
electrolyte level to fall below the top of the
battery plates. Electrolyte levels fall 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 do new batteries.
6. When the temperature falls below 65°F, the
batteries should be placed on charge as soon as
possible.
7. The tops of the batteries and battery hold-downs
must be kept clean and dry at all times to
prevent excessive self discharge and flow of
current between the battery posts and frame.
8. Follow all operating instructions, cautions, and
warnings as specified in this manual and on the
charger case.

Operating Instructions 301316H
WIRING DIAGRAM
BLACK
WHITE
BLACK
BLACK
AMMETER
DC
OUTPUT
TRANSFORMER
+
-
2
3
4
BLACK
SCR
SCR
WHITE
SHUNT
DC
FUSE BLK
RED
ORANGE
9
7
6
5
4
3
2
1
1
WHITE
BLACK
WHITE
YELLOW
BROWN
BROWN
BROWN
FUSE
FUSE
AC
AC
7
11
14
13
5
TAN WHITE
WHITE
ELECTRONIC
TIMER
8
10
12
208
SETTING
SHOWN
BLACK
YELLOW
BROWN
BLK
200-220/221-250
GREEN
VAC INPUT
6
9
208
SETTING
240
SETTING
BROWN
TAN
TAN
WHITE
BLACK
SWITCH
ON/OFF
POWER
L2200S02
PARTS LIST FOR MODEL 15510
TYPE 72EL40-10ET 208/240 VAC / 50-60 HZ
PART NO. QTY. DESCRIPTION
19721S 1 CASE ASSEMBLY
15002S 1COVER, BLUE
15009S 1 BASE, BLUE
15004S 2 PANEL, SIDE, LEFT OR RIGHT, BLUE
15008S 1 PANEL, REAR, BLUE
19476S 1 PLATE, MOUNTING HEATSINK
19602S 1 PANEL ASSEMBLY, FRONT, BOTTOM
19614S 1 PANEL ASSEMBLY, FRONT, TOP
19661S 2 RAIL, TRANSFORMER SUPPORT
19609S 1 PANEL, FUSE
19612S 1 PANEL ASSEMBLY, INNER MOUNTING, W/ WIRES
20712S 1 CORD BRACKET KIT
15395S 1 TRANSFORMER
16823S 1 AMMETER
19649S 2 HEATSINK ASSEMBLY W/ SCR
19648S 2 SCR ASSEMBLY, 55 AMP, 400 VOLT
16182S 1 FUSE, DC, 100 AMP, JJN-100
19702S 1 FUSEHOLDER, AC
19703S 2 FUSE, AC, 35 AMP, 250 VOLT, TYPE R
16070S 1 TIMER, ELECTRONIC
04715S 1 TERMINAL STRIP, 2 POLE
16222S 1SWITCH, SLIDE, DPST
02008S 2 BUSHING, 8P-2, INSULATING, DC CORD
10410S 1 STRAIN RELIEF, INSULATING, AC CORD
19599S 1 CORDSET, AC, NO PLUG
20248S 1CORDSET, AC, 250V, 30A, 6-30P PLUG
19647S 1 CONTROL CABLE ASSEMBLY
18696S 1 SHUNT, ELECTRONIC
20122S 1 CORDSET, DC, GREEN SB350 PLUG

Operating Instructions 401316H
L I M I T E D W A R R A N T Y
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
[email protected] 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 #
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.