LESTRONIC II FULLY AUTOMATIC

BATTERY CHARGER
MODEL 20330 TYPE 48LC21-6ET

Specifications
AC Input: 108-128 VAC, 12 amp, 60 Hertz, single-phase
DC Output: 48 VDC, 21 amp
Connections: Input – 6 or 9 ft. AC input cord with NEMA 5-15 grounded plug
Output – 8½ ft. or longer output cord with polarized connector

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.

Features
• Patented DV/DT electronic timer monitors battery state of charge while charging and automatically turns charger off as
battery reaches full charge.
• Compensates automatically for AC input line voltage variation by high reliability ferroresonant transformer design. Supply
voltage variation + 10% from nominal, + 1% maximum battery charger voltage variation, decreasing to + ½% at finish rate
with constant electrolyte temperature. No taps or rate controls to set.
• Automatic decrease of charge rate for superior battery life through good equalization of cells and low water use rate.
• Silicon diodes with inherent surge protection operated at a conservative percentage of their rating.
• Convection-cooled design for maximum reliability and minimum maintenance.

INTRODUCTION batteries by measuring the rate at which the battery

The Lestronic II automatic battery charger is voltage increases during charge. When the voltage
designed to recharge deep-cycle, lead-acid stops rising, the battery is fully charged and the
batteries. A ferroresonant transformer is used to charger turns off.
provide a highly reliable, line compensating unit with
a minimum of moving parts, designed for long, INITIAL INSTALLATION
trouble-free service. A patented electronic timer The AC line to which the charger is to be connected
turns the charger on and off automatically. This must be capable of supplying 15 amperes to this
DV/DT electronic timer determines full charge of the charger.

Operating Instructions 1 01732E

 The conductor with insulation having an outer
CAUTION: USE ONLY ON CIRCUITS surface that is green, with or without yellow stripe(s),
PROVIDED WITH A MAXIMUM OF 20 AMP (15 is the equipment-grounding conductor. If repair or
AMP IN CANADA) BRANCH CIRCUIT replacement of the electric cord or plug is necessary,
PROTECTION IN ACCORDANCE WITH THE do not connect the equipment-grounding connector
NATIONAL ELECTRICAL CODE ANSI/NFPA 70 to a live terminal. Refer to a qualified service agent.
AND ALL LOCAL CODES AND ORDINANCES.
Battery chargers equipped with a grounding plug as
IMPROPER CIRCUIT PROTECTION MAY RESULT
illustrated in Figure A are for use on a nominal 120
IN A FIRE.
Volt circuit. A temporary adapter, as illustrated in
The use of an extension cord with the charger Figures B and C, may be used to connect this plug
should be avoided. The use of an improper to a two-pole receptacle as shown in Figure C if a
extension cord could result in a risk of a fire or properly grounded outlet is not available. The
electric shock. If an extension cord must be used, temporary adapter should be used only until a
use a three-conductor, No. 14 AWG cord with properly grounded outlet can be installed by a
ground, properly wired, in good electrical condition qualified electrician. The green-colored rigid ear or
and keep it as short as possible. Make sure that the lug extending from the adapter must be connected
pins on the plug of the extension cord are the same to a permanent ground such as a properly grounded
number, size, and shape as that of the plug on the outlet box. Make sure that the charger is connected
battery charger. Locate all cords so that they will not to a receptacle having the same configuration as the
be stepped on, tripped over, or otherwise subjected plug.
to damage or stress.
GROUNDING METHODS
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.
Keep all charger ventilation openings at least two
inches (2") (5cm) away from walls and other objects.
Do not allow clothing, blankets, or other material to
cover the charger.
NOTE: The use of the adapter shown in Figures B
WARNING: CHARGERS CAN IGNITE and C is not permitted in Canada. If a
FLAMMABLE MATERIALS AND VAPORS. DO grounding type receptacle is not available,
NOT USE NEAR FUELS, GRAIN DUST, do not use this charger until the proper
SOLVENTS, OR OTHER FLAMMABLES. outlet is installed by a qualified electrician.

WARNING: TO REDUCE THE RISK OF AN

ELECTRIC SHOCK, KEEP THE CHARGER DRY. NORMAL OPERATION
DO NOT EXPOSE IT TO RAIN, POWER WASH The instructions printed on the charger are for
DETERGENTS OR SPRAY. FOR STORAGE, daily reference.
KEEP THE CHARGER IN A BUILDING. OUTPUT POLARITY: White, Red "+" POS.
ATTENTION: Ne pas exposer a la pluie. Black "-" NEG.

CAUTION: USE CHARGER ONLY FOR

GROUNDING INSTRUCTIONS CHARGING 48-VOLT, 24-CELL, SERIES
This battery charger must be grounded to reduce the CONNECTED WET LEAD-ACID SYSTEM WITH A
risk of electric shock. This charger is equipped with CAPACITY OF 140 TO 270 AMPERE-HOURS (20
an electric cord having an equipment-grounding HR. RATE). OTHER TYPES OF BATTERIES MAY
conductor and a grounding type plug. This plug BURST CAUSING PERSONAL INJURY AND
must be connected to an appropriate receptacle that DAMAGE.
is properly installed and grounded in accordance
with the National Electrical Code and all local codes ATTENTION: Utiliser pour charger
and ordinances. uniquement les accumulateurs au plomb à
electrolyte liquide. D'autres types d'accumu-
WARNING: IMPROPER CONNECTION OF lateurs pourraient éclater et causer des
THE EQUIPMENT-GROUNDING CONDUCTOR blessures ou domages.
CAN RESULT IN RISK OF ELECTRIC SHOCK.

Operating Instructions 2 01732E

 THE CHARGER TO OPERATE FOR MORE THAN
DANGER: RISK OF ELECTRIC SHOCK! DO 30 MINUTES WITH THE AMMETER READING IN
NOT TOUCH UNINSULATED PORTIONS OF THE EXCESS OF 25 AMPS. THIS IS MISUSE AND
OUTPUT CONNECTOR OR UNINSULATED WILL CAUSE OVERHEATING AND TRANS-
BATTERY TERMINALS. FORMER BURNOUT.
DANGER: Risque de chocks électriques. Ne 4. The charge rate will decrease to 4 to 9 amperes
for the last few hours of charge if all battery cells
pas toucher les parties non isolées du
test good.
connecteur de sorti ou les bornes non isolées de
l'accumulateur. During charge, the battery voltage increases
gradually causing the charge rate to decrease.
1. With the charger DC output cord disconnected
Good battery cells should each rise to
from the batteries, connect the input plug to a
approximately 2.5 volts DC causing the charge
properly grounded 120 Volt, 60 Hertz outlet with
rate to reduce to less than 9 amps. Each cell
the same number and size pins as the plug.
accepts charge differently; normal charging with
the ammeter reading in the 4 to 9 amps area for
WARNING: TO REDUCE RISK OF ELECTRIC
the last few hours of charge is important to
SHOCK, CONNECT ONLY TO A PROPERLY
achieve equalization of all battery cells every
GROUNDED, SINGLE PHASE (3-WIRE) OUTLET.
time the batteries are charged.
REFER TO GROUNDING INSTRUCTIONS.
As batteries age, individual cells weaken,
2. Connect the DC output plug to the battery
resulting in lower than normal finish charge
receptacle by grasping the plug body or handle
voltage. As the finish charge voltage decreases,
and pushing the plug straight into the receptacle.
the finish charge rate increases and no longer
The charger will turn on with an audible "click"
reduces into the 4 to 9 amps range on the
after a short delay if all circuits and battery
ammeter. The electronic timer still determines
voltage test good. The transformer will "hum"
when the batteries have reached their maximum
and ammeter indicate initial charge rate.
state of charge and turns the charger off. Even
though they are properly charged, older
WARNING: DO NOT DISCONNECT THE DC
batteries will gradually lose capacity, and should
OUTPUT CORD FROM THE BATTERY
be replaced when they will no longer perform as
RECEPTACLE WHEN THE CHARGER IS ON.
required.
THE RESULTING ARCING AND BURNING WILL
DAMAGE THE CONDUCTORS AND COULD The charger turns off automatically when the
CAUSE THE BATTERIES TO EXPLODE. batteries reach full charge. The necessary
DISCONNECT THE AC POWER SUPPLY CORD charge time is affected by numerous factors.
TO TURN THE CHARGER OFF BEFORE The major factors affecting the required charge
DISCONNECTING THE OUTPUT PLUG. time are battery amp-hour capacity, depth of
discharge, battery temperature and if the battery
3. Monitor the ammeter for the initial charge rate.
is new or broken in. The required charge time
The initial charge rate will vary from 16 to 25
varies with battery size and depth of discharge.
amperes depending upon the condition of the
Under normal operating conditions, the
batteries and how much the batteries have been
maximum necessary charger time is 10 to 12
discharged. Slight variations in the initial charge
hours.
rate may also result from AC input line voltages
which are higher or lower than nominal. Higher This normal charge time is for batteries which
line voltages increase the initial charge rate have been discharged to 80% of their rated
while lower line voltages reduce the charge rate. capacity. As much as 4 ADDITIONAL HOURS
may be required to properly charge batteries
If the batteries are heavily discharged and the
under the following conditions:
AC input line voltage is higher than nominal, the
initial charge rate may exceed 25 amperes. a. Heavily discharged batteries (more than
Under normal conditions, the charge rate will 80% discharged).
taper to less than 25 amperes within 30 minutes. b. Charging new batteries (batteries with less
If the ammeter still reads more than 25 amperes than 50 discharge/charge cycles).
after 30 minutes, turn the charger off by c. Charging cold batteries (ambient temper-
disconnecting the power supply cord from its atures below 65°F). When charging new or
outlet. cold batteries, a higher than normal finishing
charge voltage can be expected. This
CAUTION: TO PREVENT BATTERY results in a low finish charge rate (2 to 5
DAMAGE, CHARGER OVERHEATING, AND amps), and additional time is required to
TRANSFORMER BURNOUT, DO NOT ALLOW achieve equalization of all battery cells.

Operating Instructions 3 01732E

 Refer to a qualified service agent if the fuse when charging. Battery and/or charger
charger does not turn off within the specified damage can result.
time. 2. New batteries should be given a full charge
As batteries age, the charge rate may no longer before their first use because it is difficult to
decrease to the 6 to 10 amp finish rate. This is know how long the batteries have been stored.
normal. As battery cells wear out, they weaken 3. Limit the use of new batteries for the first 20
resulting in a lower than normal finish voltage. cycles. New batteries and older batteries that
However, the charger will still determine when have been in storage are not capable of their
the battery is as charged as it can be and then rated output until they have been discharged
turn off. Even though they are properly charged, and charged a number of times.
older batteries will gradually lose capacity, and
4. DO NOT EXCESSIVELY DISCHARGE THE
should be replaced when they will no longer
BATTERIES. Excessive discharge can cause
perform as required.
polarity reversal of individual cells resulting in
WARNING: DO NOT LEAVE THE CHARGER complete failure shortly thereafter. Heavily
discharging (over 60%) new batteries before
DC OUTPUT CONNECTOR CONNECTED WHILE
they have been broken in (approximately 20
UNATTENDED FOR TWO OR MORE DAYS IN A
cycles) can cause permanent cell damage,
ROW. SEVERE OVERCHARGING AND
resulting in reduced energy capacity and
POSSIBLE DAMAGE TO THE BATTERIES WILL
shortened life.
RESULT IF THE CHARGER ELECTRONIC TIMER
KIT SHOULD FAIL AND NOT TURN OFF, OR 5. Maintain the proper electrolyte level by adding
TURN BACK ON. water when necessary. Distilled or deionized
water is free of contaminants and preferred for
5. After the charger has turned off, disconnect the
this use. Never allow the electrolyte level to fall
DC output plug from the receptacle by grasping
below the top of the battery plates. Electrolyte
the plug body and pulling the plug straight out of
levels lower during discharge and rise during
the receptacle.
charge. Therefore, to prevent the overflow of
WARNING: TO AVOID DAMAGE TO THE DC electrolyte when charging, it is mandatory that
water be added to cells AFTER they have been
OUTPUT PLUG AND CORD, DO NOT PULL ON
fully charged; do not overfill. Old batteries
THE CORD.
require more frequent additions of water than do
new batteries.
BATTERY STORAGE MAINTENANCE 6. Hard crystalline sulfates form when batteries in
When the machine is not in use, charge the batteries storage are not maintained in a charged active
once each week. Disconnect the plug at the end of state. Internal self-discharge can bring about
the charge. the start of this condition in as little as three days
in warm temperatures. Batteries allowed to sit
PROPER CARE OF DEEP CYCLE MOTIVE unmaintained in storage will self-discharge,
POWER BATTERIES sulfate to various degrees, and lose capacity.
Repeated charging without using the batteries
Motive power batteries are subjected to severe
between charges may recover some of the lost
deep-cycle duty on a daily basis. Although these
power, range, and life, but some permanent loss
batteries are designed to withstand such duty, the
should be expected.
following precautions must be observed to obtain
good performance and maximum cycle life. 7. When the temperature falls below 65°F, the
batteries should be placed on charge as soon
CAUTION: ALWAYS WEAR PROTECTIVE after use as possible. Cold batteries require
EYE SHIELDS AND CLOTHING WHEN WORKING more time to fully recharge.
WITH BATTERIES. BATTERIES CONTAIN ACIDS 8. The tops of the batteries and battery hold-downs
WHICH CAN CAUSE BODILY HARM. DO NOT must be kept clean and dry at all times to
PUT WRENCHES OR OTHER METAL OBJECTS prevent excessive self-discharge and flow of
ACROSS THE BATTERY TERMINAL OR current between the battery posts and frame.
BATTERY TOP. ARCING OR EXPLOSION OF Electrolyte spilled on the batteries never dries or
THE BATTERY CAN RESULT. evaporates and must be cleaned off.
1. When installing new batteries, be sure the 9. All connections to batteries that are bolted must
polarity of each battery and overall battery pack be maintained clean and tight. Due to heating
is correct. Due to the electrical characteristics of and discharge rates, bolted connections loosen
this charger, it is possible to hook up one of the over time. Retighten the connections twice
6 volt batteries reverse polarity and not blow the yearly to the manufacturer's specified torque.

Operating Instructions 4 01732E

10. Follow all operating instructions, cautions, and mounted on the front panel. Electrical connections
warnings as specified in this manual, on the to the fuse wire are soldered to the middle and each
charger, and in your equipment owner manual. end. Each half of the fuse wire serves as an
individual fuse link which protects the charger in the
TROUBLESHOOTING GUIDE event one or both rectifier diodes fail, or a reverse
polarity connection is made to the batteries.
To be able to troubleshoot safely and effectively,
it is important to read this guide completely Check the fuse assembly visually for an open or
before beginning any tests. blown fuse link. If both half links of the fuse
assembly blow as soon as the DC output plug is
CAUTION: DO NOT DISASSEMBLE THE connected to the battery connector, the polarity of
CHARGER. TAKE IT TO A QUALIFIED SERVICE the batteries may be reversed. If no battery or
AGENT WHEN SERVICE OR REPAIR IS connector maintenance has been performed prior to
REQUIRED. INCORRECT REASSEMBLY MAY the fuse blowing, the charger is malfunctioning. If
RESULT IN RISK OF ELECTRIC SHOCK OR FIRE. only one half link blows, the charge rate will be low
THE FOLLOWING PROCEDURES ARE and the charger is malfunctioning.
INTENDED ONLY TO DETERMINE IF A
MALFUNCTION MAY EXIST IN THE CHARGER. CAUTION: DO NOT USE THE CHARGER IF
THE OUTPUT IS LOW. BATTERIES WILL NOT
DANGER: TO REDUCE THE RISK OF REACH FULL CHARGE, THEREBY INCREASING
ELECTRIC SHOCK, ALWAYS DISCONNECT THE POSSIBILITY OF A HARMFUL DEEP
BOTH THE POWER SUPPLY CORD AND THE DISCHARGE DURING THEIR NEXT USE.
OUTPUT CORD BEFORE ATTEMPTING ANY 3. Ammeter needle remains at more than 25
MAINTENANCE OR CLEANING. TURNING THE amps for more than 30 minutes
CHARGER OFF DOES NOT REDUCE THE RISK. This high charge rate is caused by misuse. The
charger is connected to a battery pack with a system
WARNING: DO NOT OPERATE THE voltage lower than or amp-hour capacity greater
CHARGER IF IT IS MALFUNCTIONING. than specified on the charger. If connected to a
PERSONAL INJURY OR PROPERTY DAMAGE battery system of less than 48 volts, the charge rate
COULD RESULT. will not taper and decrease to 25 amps or less within
To determine if a charger malfunction exists, identify 30 minutes. This is caused when one or more of the
the problem from the following list and refer to the batteries in the system is connected reverse polarity.
appropriate section for detailed instructions. 4. The charger does not turn off
1. CHARGER DOES NOT TURN ON New batteries or batteries charged in cold
2. CHARGER FUSE BLOWS temperatures may require an extended charge time
3. THE AMMETER NEEDLE REMAINS AT MORE to achieve full charge. However, if the charger runs
THAN 25 AMPS FOR MORE THAN 30 for longer than the maximum listed without shutting
MINUTES off, the charger is malfunctioning. Turn the charger
off by disconnecting the input plug before
4. CHARGER DOES NOT TURN OFF
disconnecting the charging plug.
5. THE BUILDING AC LINE CIRCUIT BREAKER
5. The building AC line circuit breaker or fuse
OR FUSE BLOWS
blows
If the problem is other than listed above, refer to a
This condition can be caused by a charger problem,
qualified service agent for additional troubleshooting
a "weak" fuse or circuit breaker protecting the circuit,
procedures.
or an overloaded circuit. If the building AC power
1. Charger does not turn on fuse or circuit breaker blows, connect the charger to
The DC plug must be disconnected and reconnected other outlets (on different circuits) in the building. If
to start the charger after turn off. the charger operates properly on other circuits, have
Test for a live outlet by connecting a light or a qualified electrician inspect and test the original
appliance to the same outlet. circuit. If the charger causes other fuses or circuit
breakers (in the building) to blow, the charger should
2. Charger fuse(s) blow
be tested for a problem.
The charger fuse assembly consists of a "U" shaped
wire visible through a transparent cover, and is

Operating Instructions 5 01732E

 WIRING DIAGRAMS

OPTIONS -96 & -97

L2120B26

CAPACITOR
ELEC TR ONIC TIMER
KIT

SPST RELAY
RED HEAT SINK
NO BLACK TAN ASSEMBLY
W/DIODES
ORANGE

COM BROWN TAN

1
WH ITE, RED

WHITE OR RED (+)

YELLOW
WHITE
OR BLUE

AM METER

2
T RANSFORMER
BLACK OR

WHITE
BROWN

WHITE BLACK
BLACK (-)

BLACK
GR EEN OR
GREEN/YELLOW
FUSE
PRIMARY ASSEMBLY

IN PUT
BLACK RED (SENSE)
BUSHING OUTPUT
BUSHIN G
C ASE BLACK (-)
GROUND SENSE (R ED) OUTPUT
C ORDSET
INPUT OPTION -98 W/PLUG
CORD SET

WHITE (+)
OUTPUT
PLUG
L2120B25

Operating Instructions 6 01732E

 PARTS LIST FOR LESTRONIC II CHARGER
MODEL 20330 TYPE 48LC21-6ET
120 VAC / 60 HZ

PART NO. QTY. DESCRIPTION

26896S 1 CASE ASSEMBLY, MODEL 20330

26897S 1 TRANSFORMER ASSEMBLY, 120/60
02390S 1 CAPACITOR, 6 MFD, 660 VAC/70C, 600 VAC/90C
16354S 1 HEATSINK ASSEMBLY, W/ DIODES
08776S 1 FUSE ASSEMBLY
21461S 1 AMMETER, 0-25 AMP, CORNER STUD MOUNT
16369S ALT AMMETER, 0-30 AMP, CORNER STUD MOUNT
20500S 1 ELECTRONIC TIMER KIT, 48 VDC, B.I.
02028S 2 INSULATOR BUSHING FOR AC & DC CORDSETS, 7W-2
22653S 1 AC CORDSET, 14/3, 104", 5-15P MOLDED PLUG
26748S 1 DC CORDSET, 12/2 & 16/1, 120" POWERWISE PLUG
** 26749S 1 DC CORDSET, 12/3, 48", NO PLUG
*** 30462S 1 DC CORDSET, 12/3, 75", NO PLUG
* 17305S 1 RELAY, 30 VDC, 5 PDT, 15A/125V, FLANGE MOUNT
* 26931S 1 WIRE ASSEMBLY
* 21426S 1 WIRE ASSEMBLY
* 21424S 1 WIRE ASSEMBLY
* 27189S 2 WIRE ASSEMBLY

* OPTION -96 & -97 ONLY

** OPTION -97 ONLY
*** OPTION -96 ONLY

Operating Instructions 7 01732E

 LIMITED WARRANTY
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 #
For repairs made at other than the Lester factory, Lester will provide only the replacement parts. Defective parts should be
sent with transportation charges prepaid to the Lester factory at the address noted above.
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 8 01732E