Lester X-Series SCR User manual

USER’S MANUAL
Industrial Battery Charger
Important Safety,
Installation,
Operation, and
Maintenance
Instructions
*37414*
www.LesterElectrical.com

X-Series 2 of 20 User’s Manual
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.
SAVE THIS MANUAL: Keep it in a location where it is available to anyone who may
operate the charger.

X-Series 3 of 20 User’s Manual
TABLE OF CONTENTS
CHARGER RATINGS LABEL ...................................................................................................2
TABLE OF CONTENTS.............................................................................................................3
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
LIMITED WARRANTY .............................................................................................................19

X-Series 4 of 20 User’s Manual
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.
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.
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 5 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 6 of 20 User’s Manual
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, lead-
acid 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.
Model
Number DC Output Volts DC Output Amps Amp-Hour Rating, C
20
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
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 7 of 20 User’s Manual
Part Number Battery Profile Code Battery Profile
W1 Wet, standard
A1 AGM, standard
G1 Gel, standard
Figure 4-1: Standard Battery Profile Codes and Their Corresponding Battery Profiles
To change the active battery profile on your charger, remove the charger cover and position the jumper as shown
in Figure 4-2. Profile 1 is the primary battery profile and the factory-configured jumper position. Profile 2 is the
secondary battery profile. If changed from the factory-configured jumper position, Profile 1, mark the charger
ratings label or add an additional label or tag.
Figure 4-2: Setting the Internal Battery Profile Jumper Determines the Battery Type
CAUTION: THIS CHARGER IS FOR USE ONLY ON RECHARGEABLE DEEP-CYCLE LEAD-ACID
BATTERY SYSTEMS OF THE SAME TYPE AS THE SELECTED 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 non-removable cell caps. The physical appearance of
the battery case is frequently the same as a wet battery, though the cell caps are generally not removable. Refer
to the battery manufacturer's information panel on the battery case to determine the type battery you have. If the
information panel is missing or not legible, do not use the battery.
5. OFF-BOARD (SHELF) VERSUS ON-BOARD (BUILT-IN) CHARGERS
X-Series chargers are available in either off-board or on-board configurations. Chargers configured for on-board
use are denoted as such in the type field on the charger ratings label, (for example “wet/onbrd”).

X-Series 8 of 20 User’s Manual
5.1 Off-Board Chargers
Off-board chargers are designed to be used in shelf or portable applications. They include rubber feet. If the
AC input plug is connected to AC power, a new charge cycle automatically starts when the DC output is
connected to a battery pack of the proper voltage. Disconnecting and reconnecting AC power while the DC
output remains connected to a battery pack WILL NOT automatically start a new charge cycle (unless a
storage mode condition has been met). Disconnecting the DC output from the battery pack IS REQUIRED to
automatically start a new charge cycle.
5.2 On-Board Chargers
On-board chargers are designed to be mounted on electric vehicles/equipment. They include steel feet with a
pattern that provides numerous mounting options (see Section 6.1). If the DC output is connected to a battery
pack of the proper voltage, a charge cycle automatically starts when the AC input plug is connected to AC
power (unless a safety period of time has not passed since the successful completion of the previous charge
cycle). Disconnecting the DC output from the battery pack is NOT REQUIRED to automatically start a new
charge cycle.
6. LOCATION AND INSTALLATION
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.
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 and batteries. The charger should be located in a clean, cool, dry, and well ventilated area. To permit
free airflow for convection cooling, allow 2 inches (5.08 cm) minimum between the charger ventilation openings
and any walls or other objects. Do not obstruct the airflow space around and beneath the charger. Do not allow
clothing, blankets, or other materials to cover the charger.
Install the charger in an area where the temperatures will remain within the range of -4 °F to 113 °F (-20 °C to 45
°C) and the relative humidity will remain below 95 percent (%). Exceeding these ranges will reduce the current
capacity and possibly the service life of the charger. If the charger will be operated outside of these ranges,
contact your dealer to verify if it will withstand these conditions and perform at the needed capacity.
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 manner. Contact your dealer.
WARNING: REPLACE WORN, DAMAGED, OR CUT ELECTRICAL CORDS AND PLUGS IMMEDIATELY.
WARNING: KEEP DRY; DO NOT EXPOSE TO RAIN OR SPRAY. FOR STORAGE, KEEP CHARGER IN A
BUILDING. NE PAS EXPOSER A LA PLUIE.

X-Series 9 of 20 User’s Manual
6.1 On-Board Mounting
On-board X-Series chargers are designed to be mounted on electric vehicles/equipment. They include steel
feet with a pattern that provides numerous mounting options. A dimensional drawing of the on-board
mounting pattern is provided in Figure 6.1-1.
Figure 6.1-1: On-Board Mounting Pattern
7. AC INPUT
This charger must be connected to a single-phase nominal 120 Vac, 60 Hz AC power source with a voltage of
110 Vac to 132 Vac (charge times increase at lower AC voltages). The frequency must be 57 Hz to 63 Hz.
Circuit breaker or fuse protection for the AC outlet to which the charger is connected should allow 15A per
charger. Do not overload an electrical outlet.
This charger must be grounded to reduce the risk of electric shock. It is equipped with an AC cable with an
equipment-grounding conductor and a grounding-type connector. The connector must be plugged into an
appropriate outlet that is properly installed and grounded in accordance with the National Electrical Code and 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-grounding conductor to a live terminal. Contact your dealer. This charger is equipped
with a grounding connector as illustrated in Figure 7-1 A, for use on a nominal 120 Vac, 60 Hz circuit. A
temporary adapter, as illustrated in Figures 7-1 B and C, may be used to plug this connector into a two-pole
receptacle as shown in Figure 7-1 C if a properly grounded outlet is not available (NOTE: use of an adapter as
shown in Figures 7-1 B and C is NOT permitted in Canada). The temporary adapter should be used only until a
properly grounded outlet can be installed by a qualified electrician. The green-colored rigid ear extending from the
adapter must be connected to a permanent ground such as a properly grounded outlet box.
DANGER: BEFORE USING THE ADAPTER AS ILLUSTRATED, BE CERTAIN THAT THE CENTER
SCREW OF THE OUTLET PLATE IS GROUNDED.

X-Series 10 of 20 User’s Manual
Figure 7-1: Grounding Methods
(NOTE: Use of an adapter as shown in Figures B and C is NOT permitted in Canada)
Use of an extension cord with the charger should be avoided. Use of an improper extension cord could result in a
risk of a fire and electrical shock. If an extension cord is needed, use a three-conductor, No. 14 AWG (or larger)
cord that is grounded, properly wired, and in good electrical condition, and keep the cord as short as possible.
Make sure that the pins on the connector of the extension cord are the same number, size, and shape as those
on the AC connector on the charger. Locate all extension cords so that they will not be stepped on, tripped over,
or otherwise subjected to damage or stress.
The charger includes an AC input circuit breaker to protect the charger and the system.
8. DC OUTPUT
Only charge battery packs with cell counts (CELLS) and DC voltages (DC VOLTS) equal to those listed on the
ratings label on the back of the charger.
The DC output cordset includes a commonly-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 plug for use with Club Car ® vehicles, it is important to
understand that this charger is intended for use with vehicles without an onboard computer (OBC). If the
charger is connected to a vehicle with an onboard computer, the charger will not start a charge cycle.
In addition to the battery negative (-) and battery positive (+) pins, this plug includes a third pin. This third pin
is connected to battery negative (-) inside the charger. It can be used with an optional external relay that can
be installed in the vehicle to provide lockout/interlock functionality.
Club Car ® is a registered trademark of Club Car Inc.
8.2 DC OUTPUT FUSE
The DC output fuse is a fast-acting fuse used to protect the charger and the system.
USE ONLY THE CORRECT SIZE IDENTICAL TYPE REPLACEMENT FUSES. FUSES ARE AVAILABLE
FROM A QUALIFIED SERVICE TECHNICIAN.