Lester 19300 Operation, T Roubleshooting And Replacement Parts Manual
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Lester 19300 Operation, T Roubleshooting And Replacement Parts Manual

Lester 19300 Operation, T Roubleshooting And Replacement Parts Manual

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TROUBLESHOOTING, REPAIR, AND REPLACEMENT
GUIDE FOR MODEL #19300 BATTERY CHARGER
PLEASE SAVE THESE IMPORTANT SAFETY 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.
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.

TABLE OF CONTENTS

INTRODUCTION ....................................................................................................................... 2
PROPER CARE OF MOTIVE POWER BATTERIES................................................................. 2
TROUBLESHOOTING GUIDE .................................................................................................. 3
1.
CHARGER DOES NOT TURN ON............................................................................ 4
2.
CHARGER FUSE BLOWS ........................................................................................ 5
3.
AMMETER READS 25 AMPS FOR MORE THAN 30 MINUTES .............................. 6
4.
CHARGER OUTPUT IS LOW ................................................................................... 6
5.
CHARGER TURN-OFF MALFUNCTIONS ................................................................ 6
6.
AC LINE FUSE OR CIRCUIT BREAKER BLOWS .................................................... 8
COMPONENT TEST PROCEDURES ....................................................................................... 9
7.
ELECTRONIC CHARGE CONTROLLER TESTING ................................................. 9
8.
TRANSFORMER TESTING .................................................................................... 12
9.
DIODE ASSEMBLY TESTING ................................................................................ 14
10.
CAPACITOR TESTING ........................................................................................... 17
11.
AC INPUT CIRCUIT TESTING................................................................................ 19
12.
DC OUTPUT CIRCUIT TESTING............................................................................ 20
COMPONENT REPLACEMENT PROCEDURES ................................................................... 21
13.
ELECTRONIC CHARGE CONTROLLER REPLACEMENT .................................... 21
14.
DIODE ASSEMBLY REPLACEMENT ..................................................................... 23
15.
CAPACITOR REPLACEMENT................................................................................ 25
16.
AC INPUT AND DC OUTPUT CORD REPLACEMENT .......................................... 26
17.
FUSE ASSEMBLY REPLACEMENT....................................................................... 27
CHARGER WIRING DIAGRAM............................................................................................... 28
CHARGER COMPONENTS EXPLODED VIEW ..................................................................... 29
SERVICE PARTS LIST ........................................................................................................... 29
www.lesterelectrical.com
DO NOT DISCARD THIS MANUAL AFTER READING.
1
*35827*
35827_A

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  • Page 1: Table Of Contents

    *35827* TROUBLESHOOTING, REPAIR, AND REPLACEMENT GUIDE FOR MODEL #19300 BATTERY CHARGER PLEASE SAVE THESE IMPORTANT SAFETY 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.

  • Page 2: Introduction

    INTRODUCTION This battery charger is designed to recharge deep-cycle, wet lead-acid batteries. A ferroresonant transformer is used to provide a highly reliable, AC line voltage-compensating unit with a minimum of moving parts, designed for long, trouble-free service. An electronic charge controller turns the charger on and off automatically. This controller determines full charge of the batteries by measuring the rate at which the battery voltage increases.

  • Page 3: Troubleshooting Guide

    CHARGER FOR USE OTHER THAN THAT FOR WHICH IT WAS INTENDED, REPAIRS BY PERSONS NOT QUALIFIED, OR NOT USING ORIGINAL EQUIPMENT REPLACEMENT PARTS WILL VOID THE WARRANTY AND LESTER LIABILITY. DANGER: HIGH VOLTAGE! WITH THE CHARGER ON, THE INTERNAL CHARGER CAPACITOR VOLTAGE IS APPROXIMATELY 660 VOLTS.

  • Page 4: Charger Does Not Turn On

    CHARGER DOES NOT TURN ON In normal operation, the charger DC output plug must be connected to the batteries and the AC input cord must be connected to a live power source in order to turn the charger on. A time delay of three to five (3-5) seconds is provided to allow adequate time to make a secure connection before the charger turns on.

  • Page 5: Charger Fuse Blows

    Relay closes, and transformer hums, but ammeter does not register If the relay closes and the transformer hums, the charger AC circuit and electronic charge controller are functioning properly. If the ammeter does not register, a problem could exist with the following components: •...

  • Page 6: Ammeter Reads 25 Amps For More Than 30 Minutes

    AMMETER READS 25 AMPS FOR MORE THAN 30 MINUTES This high output condition is caused by misuse, connecting the charger to an incorrect battery system that is lower than what is rated for the charger. A common error is to install one or more of the batteries in a battery pack reverse polarity.
  • Page 7 Charger turns off too soon Check to be sure the AC input cord is securely connected to a live outlet. To determine if the charger did shut off too soon, disconnect and reconnect the charger DC output plug. This will restart the charger.

  • Page 8: Ac Line Fuse Or Circuit Breaker Blows

    Charger runs too long but does turn off In the event of AC power interruption when the charger is on, the charger will automatically restart when AC power is restored. This power outage can make the apparent charge time seem longer than the actual charge time, which has a maximum run time of 16 hours. To check for AC power interruptions, plug an electric clock into the same outlet to which the AC input cord is connected.

  • Page 9: Component Test Procedures

    CHARGER FOR USE OTHER THAN THAT FOR WHICH IT WAS INTENDED, REPAIRS BY PERSONS NOT QUALIFIED, OR NOT USING ORIGINAL EQUIPMENT REPLACEMENT PARTS WILL VOID THE WARRENTY AND LESTER LIABILITY. DANGER: HIGH VOLTAGE! WITH THE CHARGER ON, THE INTERNAL CHARGER CAPACITOR VOLTAGE IS APPROXIMATELY 660 VOLTS.
  • Page 10 Relay Not Closing Connect the AC input cord to a live outlet and DC output plug to the battery receptacle. Using an appropriate multi-meter, set it to measure AC volts on a scale large enough to measure 120 VAC. Place the two meter probes across point A (screw head) and B (dual QD terminal) as shown in Figure.
  • Page 11 CAUTION: NEVER ‘ROCK’ OR ‘WALK’ THESE TERMINALS TO GET THEM ON OR OFF OF THE RELAYS. USE A ‘DIRECT’ IN/OUT MOTION WHEN INSTALLING AND REMOVING THESE TERMINALS. The goal is to minimize widening or spreading of the ‘curl’ of the female terminal that reduces the clamping strength and area of surface contact with the blade in the relay.

  • Page 12: Transformer Testing

    Remove the Phillips screws that retain the cover, and then remove the cover. Remove the two screws that hold the controller to the enclosure. Stuck relay contacts may open if jarred, so gently move the controller to access the points as shown in Figures 7F and 7G. With a multi- meter set to measure resistance, measure across the relay contacts as shown in Figure 7F.
  • Page 13 CAUTION: DISCONNECT BOTH AC INPUT AND DC OUTPUT CORDS FROM ALL POWER SOURCES BEFORE YOU PERFORM THIS TEST. Remove the Phillips screws that retain the cover, and then remove the cover. Locate the transformer output leads that attach to the rectifier/diode assembly at the rear of the case as shown in Figure 8, then remove the 11/32 nuts that retain these leads.

  • Page 14: Diode Assembly Testing

    Example: the meter reading displayed in Figure 8 indicates this transformer has an output of 90.9 volts AC. This is within the range of 83 to 97 volts anticipated, thus this transformer is good. Charger DC voltage AC volt output with a good AC volt output with capacitor rating capacitor...
  • Page 15 Remove the Phillips screws that retain the cover and then remove the cover. Locate the diode assembly at the rear of the case as shown highlighted in Figure 9A. Remove the 11/32” nuts that retain the transformer output leads to the heatsink assembly and then position these leads so that they are at least 1/4 inch away from any objects near them.
  • Page 16 For the next test we will reverse the polarity of the meter clips as shown in Figure 9C. The red positive (+) lead now attaches to the center DC output terminal and the black negative (-) lead attaches to the upper diode. Do not change your meter settings; they remain the same for both tests as shown in Figures 9B and 9D.

  • Page 17: Capacitor Testing

    CAPACITOR TESTING The purpose of this test is to prove if the capacitor is good, or has failed ‘open’ or ‘shorted’. The capacitor in this charger is a tuning device that maximizes the current output of the transformer. Failure of the capacitor will decrease the DC current output of the transformer from 20+ amperes maximum to zero amperes.
  • Page 18 CAUTION: NEVER ‘ROCK’ OR ‘WALK’ THESE TERMINALS TO GET THEM ON OR OFF OF RELAYS. USE AS ‘DIRECT’ IN/OUT MOTION WHEN INSTALLING AND REMOVING THESE TERMINALS. Your goal is to minimize widening or spreading of the ‘curl’ of the female terminal that reduces the clamping strength and area of surface contact with the blade in the capacitor.

  • Page 19: Ac Input Circuit Testing

    AC INPUT CIRCUIT TESTING CAUTION: TO REDUCE THE RISK OF ELECTRIC SHOCK, CONNECT ONLY TO A PROPERLY GROUNDED OUTLET! Check to be sure that the AC input cord is securely connected to a live AC outlet. When three- prong to two-prong adapters are used, they tend to work loose, resulting in a poor connection. Check the AC line fuse or circuit breaker and, if possible, measure the AC line voltage at the outlet to be sure AC power is present.

  • Page 20: Dc Output Circuit Testing

    DC OUTPUT CIRCUIT TESTING First verify that the battery pack voltage is present at the battery receptacle. If it is not, a fault has occurred in the vehicle’s wiring. Remove the Phillips screws that retain the cover, then remove the cover. Connect the DC output plug to the battery receptacle and with a multi- meter measure the voltage inside the charger where the WHITE and BLACK wires of the DC output cord attach.

  • Page 21: Component Replacement Procedures

    CHARGER FOR USE OTHER THAN THAT FOR WHICH IT WAS INTENDED, REPAIRS BY PERSONS NOT QUALIFIED, OR NOT USING ORIGINAL EQUIPMENT REPLACEMENT PARTS WILL VOID THE WARRENTY AND LESTER LIABILITY. DANGER: HIGH VOLTAGE! WITH THE CHARGER ON, THE INTERNAL CHARGER CAPACITOR VOLTAGE IS APPROXIMATELY 660 VOLTS.
  • Page 22 the 3/8-inch self-threading screws into the mounting locations. The screws will thread into a metal bracket located inside the plastic tray. Tighten until screws are flush and snug against the enclosure. Do not over tighten. Using longer screws will damage the electronics. 5.

  • Page 23: Diode Assembly Replacement

    6. Connect the BLACK lead of the AC input cord to the common (COM) terminal of the relay on the electronic charge controller and the WHITE lead to the dual QD terminal (B) on the controller as shown in Figures 13C and 13D. Connect either transformer primary lead to the dual QD terminal (B), and the remaining primary lead to normally open (NO) terminal on the relay.
  • Page 24 1. Disconnect the charger’s AC input cord from its outlet and the DC output plug from the battery receptacle. 2. Remove the Phillips screws that retain the cover and then remove the cover. 3. Disconnect all wires from the existing heatsink. 4.

  • Page 25: Capacitor Replacement

    CAPACITOR REPLACEMENT To replace the capacitor, follow the step-by-step procedures listed below. CAUTION: DISCONNECT BOTH AC INPUT AND DC OUTPUT CORDS FROM ALL POWER SOURCES. POWER IS NOT NEEDED FOR THIS REPLACEMENT. 1. Disconnect the charger’s AC input cord from its outlet and the DC output plug from the battery receptacle.

  • Page 26: Ac Input And Dc Output Cord Replacement

    AC INPUT AND DC OUTPUT CORD REPLACEMENT To replace either the AC input or DC output cord, follow the step-by-step procedures listed below. CAUTION: DISCONNECT BOTH AC INPUT AND DC OUTPUT CORDS FROM ALL POWER SOURCES. POWER IS NOT NEEDED FOR THIS REPLACEMENT. 1.

  • Page 27: Fuse Assembly Replacement

    FUSE ASSEMBLY REPLACEMENT CAUTION: A BLOWN FUSE INDICATES A FAILURE IN THE CHARGING CIRCUIT. LOCATE AND CORRECT THE CAUSE OF FAILURE BEFORE REPLACING THE FUSE ASSEMBLY AND OPERATING THE CHARGER. A blown fuse is normally caused by a short in the DC output cord, a shorted diode, or a reverse polarity connection to the batteries.

  • Page 28: Charger Wiring Diagram

    CHARGER WIRING DIAGRAM www.lesterelectrical.com 35827_A...

  • Page 29: Charger Components Exploded View

    DC CORDSET, 12/2, 108” SB50 GRAY, OPTION –03 36174-13S DC CORDSET, 12/2, 108” SILICONE RUBBER PLUG, OPTION -01 36182-13S DC CORDSET, 12/2, 108” LESTER PLUG, OPTION -02 07785-14S DC CORDSET, 12/2, 108” SB 175 GRAY, OPTION -04 35446-08S AC CORDSET, 16/3, 97” W/BUSHING & NEMA 5-15P...

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