LESTRONIC DV AUTOMATIC 12 OR 24 VOLT DUAL OUTPUT DUAL MODE BATTERY CHARGER MODEL TYPE 12/24EL40-10ET

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1 LESTRONIC DV AUTOMATIC 12 OR 2 VOLT DUAL OUTPUT DUAL MODE BATTERY CHARGER MODEL TYPE 12/2EL0-10ET 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 CAUTION: MAKE SURE THE INPUT VOLTAGE SELECT SWITCH IS PROPERLY SET FOR THE MEASURED AC INPUT VOLTAGE. SET THE SELECT SWITCH TO 100 TO 125 FOR MEASURED AC INPUT VOLTAGES IN THIS RANGE, AND SET THE SWITCH TO 200 TO 250 FOR MEASURED AC INPUT VOLTAGE IN THIS RANGE. NO ADJUSTMENT IS REQUIRED FOR 50 OR 60 HERTZ INPUT FREQUENCY. The charger battery type selector switch must be set correctly to charge either wet, or sealed, including gel cell, lead-acid batteries. Sliding the switch to GEL, SEALED or MAINTENANCE-FREE charges the battery to a maximum of 2.38 volts per cell. The LIQUID or WET ELECTROLYTE setting allows the battery to charge to 2.5 to 2.6 volts per cell. Remove the lower front panel to verify or change the mode setting for the specific battery type. WARNING: OPERATING THE CHARGER WITH THE INCORRECT MODE SWITCH SETTING COULD CAUSE THE BATTERIES TO RUPTURE OR EXPLODE. Move switch to UP position for GEL, SEALED, or MAINTENANCE-FREE battery Move switch to DOWN position for WET CONVENTIONAL LIQUID ELECTROLYTE battery This model charger will automatically adjust its output voltage to properly charge either 12 volt 6 cell, or 2 volt 12 cell series-connected, lead acid battery systems. Either the 12 volt or 2 volt indicator light will glow RED to indicate the charging voltage when (1) the output plug is connected to the battery system, (2) the input cordset to a live input power circuit, and (3) the power switch is in the "AUTO (l)" position. GROUNDING INSTRUCTIONS This battery charger must be grounded to reduce the risk of electric shock. It is equipped with an equipment-grounding conductor that must be Operating Instructions 1 011E

2 connected to a proper electrical ground or earth. The conductor with insulation having an outer surface which is green, with or without yellow stripe(s), is the equipment-grounding conductor. Do not connect the equipment-grounding conductor to a live terminal. If the supply cord of this equipment is damaged, it must be replaced with an original equipment manufacturer supplied cord or other approved cord by a qualified/licensed person. DANGER: IMPROPER CONNECTION OF THE EQUIPMENT GROUNDING CONDUCTOR CAN RESULT IN THE RISK OF AN ELECTRIC SHOCK. NORMAL OPERATION Refer to the instructions on the equipment, charger and battery before every use. 1. Connect the input supply cord to a properly grounded AC input supply that matches the input voltage select switch setting. The transformer may hum slightly at this time. 2. Connect charger output connector to the battery charging connector. CAUTION: MAKE SURE THE BATTERY SYSTEM IS A 12 VOLT 6 CELL, OR 2 VOLT 12 CELL, SERIES-CONNECTED, RECHARGEABLE, LEAD ACID SYSTEM OF AMP-HOUR (6 HR. RATE) CAPACITY. MAKE SURE THE BATTERY TYPE SELECTOR SWITCH IS PROPERLY SET FOR THE TYPE OF BATTERY TO BE CHARGED. DANGER: RISK OF ELECTRIC SHOCK! DO NOT TOUCH UNINSULATED PARTS OF THE CHARGER OUTPUT CONNECTOR, BATTERY CONNECTOR OR BATTERY TERMINALS. WARNING: INSPECT AND REPLACE IMMEDIATELY ALL ELECTRICAL CONNECTORS AND PLUGS THAT ARE CRACKED, CORRODED OR DO NOT MAKE PROPER ELECTRICAL CONTACT. USE OF A DAMAGED OR DEFECTIVE CONNECTOR MAY RESULT IN ELECTRICAL SHOCK, OVERHEATING AND FIRE. 3. Move the "POWER" switch to "AUTO, (l)". The ammeter needle may bounce slightly and either the 12 volt or 2 volt light will glow. Monitor the indicator lights for correct battery selection. A deeply discharged 2 volt battery may cause the 12 volt light to glow for a short time before changing to the 2 volt light. CAUTION: IF CONNECTION TO A 12 VOLT BATTERY CAUSES THE 2 VOLT LIGHT TO GLOW, TURN THE POWER SWITCH TO "OFF, (O)", THEN TURN BACK ON TO RESTART THE CHARGER. IF THE 12 VOLT BATTERY STILL CAUSES THE 2 VOLT LIGHT TO GLOW, MOVE THE POWER SWITCH TO "OFF, (O)", AND DO NOT USE THE CHARGER UNTIL THE PROBLEM IS CORRECTED.. The charger will turn on and start charging after a short delay, the ammeter will indicate the initial charge current and the transformer hum may increase. Monitor initial charge current. WARNING: 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 THE CONNECTORS MUST BE DISCONNECTED BEFORE THE CHARGER AUTOMATICALLY SHUTS OFF, FIRST TURN THE CHARGER OFF BY MOVING THE POWER SWITCH TO "OFF, (O)", OR DISCONNECTING THE POWER CORD. 5. Monitor the ammeter for the correct initial charge current. Correct initial charge current should be about 0 amps. As the battery reaches approximately 70% of full charge, the battery charge current gradually decreases to a reading determined by the battery type switch setting and the condition of the batteries. Replaceable Electrolyte Wet Lead Acid Batteries With healthy batteries, the charging current will decrease to between 9 and 11 amps and remain until the charger turns off. As replaceable electrolyte deep cycle batteries lose capacity, the charge rate may no longer decrease to this reading. The charger will still determine when the batteries are as charged as they are capable of being and will turn off. When battery capacity has decreased to where the charger is no longer able to taper down to less than 1 amps, or the batteries will no longer perform as desired, they should be replaced. Gel Cell and Sealed Deep Cycle Batteries The charging current will decrease to near zero and remain there until the charger turns off. Gel cell deep cycle batteries will still taper to near zero charge current even as they wear out and lose capacity and range. As sealed deep cycle batteries lose capacity and range, the charge current may no longer decrease to this low of a reading. The charger will still determine when the batteries are as charged as they are capable of being and turn off. When the batteries will no longer perform as desired, they should be replaced. Operating Instructions 2 011E

3 Charger is equipped with a temperature sensor which automatically turns charger off if it overheats. Should charger turn off before batteries are fully charged, check to be sure all ventilation openings are free from obstructions. After charger cools down to a safe temperature, it will automatically restart. If charger repeatedly overheats, refer to a qualified service agent. 6. Charger turns off automatically when batteries are fully charged. Charge time varies with battery size and depth of discharge. Allow 8 hours for normal charging. Larger batteries (greater than 50 ampere-hours) or severely discharged batteries may require up to 18 hours to be properly charged and equalized. If the charger operates up to 18 hours and is unable to fully charge the batteries, an internal timer turns the charger off. 7. After the charger has turned off, as indicated by the ammeter reading to drop to zero (Note: the RED light will glow until the power switch is switched to "OFF"), move the POWER switch to "OFF, (O)", disconnect AC cord first, then the DC output cord from the charging receptacle. WARNING: GEL CELL AND SEALED BATTERIES, WHEN REACHING A NEAR CHARGED CONDITION, MAY CAUSE A ZERO OR NEAR ZERO READING ON THE AMMETER BEFORE THE CHARGER HAS TURNED OFF. WARNING: DO NOT LEAVE THE DC OUTPUT CONNECTOR PLUGGED IN WHILE UNATTENDED FOR MORE THAN TWO (2) DAYS. SEVERE OVERCHARGING AND DAMAGE TO THE BATTERIES MAY RESULT IF THE CHARGER DOES NOT TURN OFF. BATTERY STORAGE MAINTENANCE When the equipment is not in use, charge the batteries once each week. TROUBLESHOOTING GUIDE The charge rate remains at 0 amps A battery system fault exists if the charger does not decrease below 0 amps. This is caused when the battery system voltage remains too low. The most common error is to install one or more 6-volt batteries in the battery system with the polarity reversed. Measure the battery system voltage while charging. If the charging voltage does not increase to 2.3 volts per cell (13.6 VDC for 6 cell 12 volt systems, 27.6 VDC for 12 cell 2 volt systems), the battery system voltage is too low, failed or incorrect and must be corrected before using the charger. Hissing sound heard from sealed batteries during charge Sealed batteries are pressure valve regulated to release excess internal pressure. Verify that mode switch is properly set for sealed batteries. Measure charging voltage at battery system and verify this measured voltage does not exceed battery manufacturer's recommended cycling use, maximum charging voltage. Fault in battery exists if measured voltages OK. 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 charged and discharged a number of times.. 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 in replaceable electrolyte batteries 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. Operating Instructions 3 011E

4 6. When the temperature falls below 65 F, the batteries should be placed on charge as soon after use as possible. 7. Should a 2V sealed battery, when it has been completely discharged, fail to gain sufficient voltage when placed on charge causing the charger to stay in the 12V charging mode for an extended time, the following steps may cure the problem: Turn the power switch to "OFF, (O)", disconnect the charger from the AC supply and battery. Remove the lower front panel and set the charge mode switch to "REPLACEABLE ELECTROLYTE" type. Replace the lower panel, reconnect charger to the battery and AC supply and restart the charger by turning the power switch to "AUTO, (l)". If the battery voltage rises and the charger indicates a 2V battery within a short time, follow the above instructions for setting the charge mode switch and set the switch back to "GELLED BATTERIES" and continue the charge cycle. If the battery voltage does not rise to the 2V range, set the charge mode back to the "GELLED" mode, but discontinue the charge and check the battery for problems. Replace the battery, if necessary. Operating Instructions 011E

5 WIRING DIAGRAM 100/125 V 200/250 V FUSE SWITCH 15 AMP BROWN BROWN 2 26 AC 25 VOLTS INPUT BLUE 11 BLUE /125V SETTING SHOWN FUSE 15 AMP (POLES #13 &#26 ON SWITCH MOUNT TO THE TOP IN PANEL OPENING) TRANSFORMER TAN TAN SCR SCR YELLOW SHUNT NATURAL DC FUSE RED 9 ORANGE YELLOW 3 BROWN 2 BROWN 1 BLK J ELECTRONIC TIMER AMMETER BLK 3 5 RED BROWN 6 YELLOW 7 ORANGE 1 GREEN 2 DC OUTPUT + - BATTERY SELECT GREEN/YELLOW 12 GROUND L2115S17 PARTS LIST FOR MODEL TYPE 12/2EL0-10ET OR VAC / HZ PART NO. QTY. DESCRIPTION 20989S 1 CASE ASSEMBLY 16605S 1 TRANSFORMER ASSEMBLY 16823S 1 AMMETER 11251S 2 HEATSINK ASSEMBLY 1675S 1 ELECTRONIC TIMER ASSEMBLY 1590S 1 BATTERY VOLTAGE SELECT, ELECTRONIC BOARD 02028S 1 BUSHING, INSULATOR, 7W-2 FOR AC CORDSETS 02009S 1 BUSHING, INSULATOR, 8P-2, FOR DC CORDSETS 1961S 1 CONTROL CABLE ASSEMBLY 20968S 1 CORDSET, AC, 2.5mm3, NO PLUG 19766S 1 CORDSET, DC, SB-175 PLUG, 8/2, 126" 15897S 1 FUSEHOLDER 1126S 1 FUSE, DC, 80 AMP, JJN S 2 FUSE, AC, 15 AMP, MDA S 1 SHUNT, ELECTRONIC 2017S 1 CORDSET, DC, NO PLUG, 8/2, 126" 2097S 1 CORDSET, DC, SB-175 PLUG, RED, 8/2, 126" 17558S 1 SWITCH, 16A/250 VAC Operating Instructions 5 011E

6 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 ( ) or by ing and send the defective unit with transportation charges prepaid to: Lester Electrical 625 West A Street Lincoln, NE 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. Operating Instructions 6 011E

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