How To Wire Your New Lester Summit Series II Golf Cart Battery Charger – 650W
This is a resource for those needing direction on how to wire their new Lester Summit Series II Battery Charger – 650W. Because of their excellent design, these universal units work great in all applications though they do require some configuring.
As is the trend, Lester does not include multi-page owners manuals in their products any longer. Since Pete’s gets a lot of calls concerning this issue we are publishing these directions here for your convenience.
Note:These wiring instructions will only apply to the Summit Battery Charger 650W version of this charger. If you own the 1050W 24 Volt, 36 Volt or 48 Volt version please refer to this How To Installation Article for the 1050W Summit Series II Battery Charger.
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First, make sure you have the correct charger and DC side cord set for your application. Refer to the DC side cord set legend below. Double check the golf cart charger receptacle on your golf cart if you intend to use in an off-board application. Otherwise it is pretty straight forward to install and use in an on-board application. All on-board applications will simply require a ring terminal DC cord set to wire to the main positive and negative terminals on the battery bank.
Proper installation is important to achieve optimum performance and life from your new charger. Always allow for as much free air space around the charger as possible. See the best mounting orientations for this charger are in Figure 2-1. The best way to mount the charger for on-board use is to bolt it to a 0.1 inch (2.5 mm) minimum thick metal plate. This provides both a strong base and good thermal conductive cooling. A poor thermal conductive material is plastic or wood though charger should still perform well.
Charger dimensions and mounting hole locations are below in Figure 2-2. For off-board applications an optional handle is available for ease in carrying. The charger case also has routing and securing locations for the AC and DC cord sets when they need routing to the opposite ends. See Figure 2-3.
2. How To Route AC and DC Side Battery Charger Cord set
The proper way to route the cord sets for optimal fit, function and performance will depend on the application (on-board vs off-board). See Figure 2-3 below.
3. Off-board (shelf) Vs On-board (built-ins) Chargers
This section describes how the charger operates in the Off-board or On-board mode. Based on your application, you can change this setting via the ChargerConnect app under “System Profile” Learn More About the App Now – Then Tap To Get the App
The factory configures the charger per the request on the original order to Lester Electrical. The factor sets the charger for mounting on-board a battery powered vehicle/machine or for off-board use in a shelf or portable application per that same order to the manufacturer. Before (1) using the charger for the first time or (2) using the charger with a battery pack of a different type or capacity, go to the ChargerConnect app. Verify that the active battery profile the system settings that should match your application. Lester Summit II Series Battery Chargers Battery Profile Quick Reference
Off-board chargers function in shelf or portable applications. If the AC input plug connects to AC power, a new charge cycle automatically starts when the DC output connects 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. YOU MUST disconnect the DC output from the battery pack to automatically start a new charge cycle.
On-board chargers are for mounting on electric vehicles/equipment. When you connect the DC output to a battery pack of the proper voltage, a charge cycle automatically starts when you connect the AC input plug 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 A REQUIREMENT to automatically start a new charge cycle.
4. – Battery Chemistry and Types
Battery Type – These charger contain multiple battery profiles for different battery types (wet/flooded, AGM, and gel) and capacities. New Summit Series II Golf Cart Battery Chargers from Battery Pete’s come set-up for a basic flooded-battery. The factory configures the charger with the active battery profile per the PO to Lester Electrical.
We recommend that you use the ChargerConnect app to verify that you are using the proper active battery profile before using the charger for the first time or using the it with a battery pack of a different chemistry or capacity. If the proper battery profile is not available on the charger, use the ChargerConnect app which provides other selections from the cloud. If still not found (ex. specific lithium ion brand),Contact Lester Electrical for more information.
THIS CHARGER IS FOR USE ONLY WITH BATTERY SYSTEMS OF THE SAME TYPE AS THE ACTIVE BATTERY PROFILE. BATTERIES IMPROPERLY MATCHED WITH THE CHARGER MAY BURST CAUSING PERSONAL INJURY AND DAMAGE TO THE BATTERIES OR CHARGER.
Special Note – If you change the active battery profile, we suggest you mark the charger ratings label or add an additional label or tag for future reference.
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Battery manufacturers frequently use the same battery cases for different battery types. Wet/flooded batteries have removable cell caps. You will replace electrolyzed water (a result of discharging and charging the battery) thru these openings.
Sealed (AGM and gel) batteries are similar in physical appearance to 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 of battery in your application. If the sticker is not readable or is missing, we suggest you do not use the
battery charger until you can verify the specifics of the battery in your application. If you have questions regarding which battery profile to select for use with your particular battery pack. If you purchased your new golf cart battery charger from us by all means give us a call to help walk you through this process. Otherwise we suggest you contact the company you purchased the charger from and if need be Lester Electrical directly for further assistance.
5. AC Power Input
This charger operates at 50-60 hertz, with an AC input rating of 100-240 volts, single-phase. It has an AC operating range of 85-265 volts, 45-65 hertz. The Summit Series II comes with an IEC 60320 C16 inlet for the AC input power as shown below. This allows the AC power cord set to work with a proper plug compatible with your local electrical codes. The AC power cord set must be a minimum of 18 AWG (1.0 mm2) for proper operation. An AC cord clamp is also comes with the cord to keep the AC power cord in the IEC connector.
Special Note – For those who require an extension cord, strive to make the distance as short as possible and use the thickest industrial cord you can. This is because you will experience voltage drop the further the charger is from the power supply outlet. Below 108 volts, the charger may reduce output power.
6. How To Disconnect AC Power From The Lester Summit II Golf Cart Battery Charger
See Image below. This is the AC power cordset inlet. To disconnect or connect you simply need to loosen the screw on the side of the clamp. Then firmly grab the IEC connector with your fingers and pull. To install or plug back in make sure you push the plug into the charger completely. Then you may tighten the AC cord clamp to secure the AC power cord to the charger.
Plug the AC power cord set into a properly installed and grounded outlet. If this charger includes the UL Listed symbol on its ratings label, it comes with a cord set for connection to outlets operating at nominal 120 volts (or 240 volts as appropriate). If the input plug does not fit the power outlet, contact Lester Electrical for the proper cord set terminating in an attachment plug of the proper configuration for the power outlet.
6. How To Connect DC Power Cord To The Lester Summit II Series Golf Cart Battery Charger
WARNING – CHARGER DC CORD SET MUST HAVE A MINIMUM OF 12 AWG WIRE SIZE FOR PROPER HEAT DISSIPATION ON 36V AND 48V SYSTEMS AND A MINIMUM OF 10 AWG WIRE SIZE FOR 24V SYSTEMS. TO PREVENT RISK OF FIRE, DO NOT USE SMALLER GAUGE WIRE.
The DC side cord set attaches to the external DC terminal block on the battery charger. See Figure 6.2-1 above. Remove the connection cover (if pre-installed) to expose the DC terminal block. Based on the DC cord connector/plug/terminals your application will require will determine proper wiring of the device. Use Dc Side Common Connector Legend shown below to determine the correct wiring configuration for your golf cart battery charger receptacle plug connector or onboard application.
The DC output cordset includes a connector, plug, or terminals. The polarity of the charger DC connector/plug/terminals must be the same as the battery connector/receptacle/terminals. The BLACK DC cable must be connected to the battery negative (-), and the WHITE or RED DC cable must be connected to
the battery positive (+). The charger will not operate if the polarity is reversed.
Once you have determined the proper wiring configuration you may proceed to then attach the DC side cord set wires as shown in images. Refer to figure 6.2-2. for further assistance. Installation will require a #2 Phillips head screw driver. DO NOT OVER TIGHTEN SCREWS OR YOU WILL RISK DAMAGE TO THE DC SIDE JUNCTION BOX. ( Proper Torque settings for the positive and negative terminal screws are to be 18 in-lbs (2.0 Nm). The lockout and external temperature sense terminal connections is to be 12 in-lbs (1.35 N-m).
Next place the strain relief over the DC cord set cable/wires on the side of the DC terminal block where the cord set will exit junction box. When
individual wires are used for on-board applications, place the foam rubber gasket that comes on the cord set under the strain relief, center the wires, and then tighten the strain relief screws and torque them to 9 in-lbs (1 N-m). This prevents the wires from getting pinched on the side of the strain relief when tightened. Replace
the terminal block cover, and torque the cover screws to 9 in-lbs (1 N-m).
Special Note For Ezgo Golf Cart Owners
When installing an “E-Z-GO 3-Pin Molded RXV & 48V TXT” DC cordset in the field, for the vehicle lockout to function correctly, you must upload a new System Profile to the charger via the ChargerConnect app by (1) downloading the appropriate System Profile from the “Cloud Profiles” tab on the “System Profiles” screen or (2) uploading the System Profile to the charger from the “Device Profiles” tab on the “System Profiles” screen.
“If this DC cord set was factory-installed, the appropriate System Profile was already uploaded to the charger at the factory.”
7. – Vehicle Lockout Control (Optional)
The charger lockout/interlock control signal can be interfaced with the vehicle/equipment to prevent use/movement of the vehicle while the charger is in use. The lockout control signal, available on Terminal 2 on the DC terminal block (see Figure 6.2-1), is internally pulled high through a 10k ohm resistor to battery positive (+) when lockout is not active and is pulled low to < 1 Vdc when lockout is active. The lockout control signal is typically interfaced with the vehicle motor speed controller.
If you are uncertain of how to interface the lockout control signal with your vehicle, please contact your vehicle dealer.
(1) If the charger is configured for on-board use, the lockout control signal will be active while AC power is applied to the charger.
(2) If the charger is configured for off-board use, the lockout control signal will be active while a valid battery is connected to the charger.
Based on your application, you can configure the charger as on-board or off-board via the ChargerConnect app under “System Profile”.
8. – How To Use The Optional External Port On Your Summit II Battery Charger
The charger has an external port with a sealed DB9 (DE9) connector located near the DC terminal block which is used for the remote LED and/or CAN communication cable assemblies. When this port is not being used, leave the protective cover over the connector to keep moisture and debris out of the connector.
When mounting the Summit Battery Charger 650W on-board a vehicle where the charger LEDs are not visible, a remote LED cable assembly can be used. Attach the remote LED cable assembly to the external port on the charger and hand tighten the connector mounting screws. The LED end of the cable assembly is to be rear mounted through a hole on the vehicle or it can be attached to a panel which mounts to the vehicle. Install the remote LED assembly as shown above.
Resource – Remote LED Information
Remote LED Status and Faults
When an optional bi-color remote LED cable is attached to the external port, the LED functionality is slightly different from the built-in LEDs and is outlined below and in the following table.
FAULT (Red) – Indicates when a charger or battery fault has occurred. See ChargerConnect App for fault description.
CHARGE STATUS (Amber) – Indicates charge cycle status.
CHARGE COMPLETE (Green) – Indicates when a charge cycle completes successfully, when an extended Balance/Equalize charge cycle phase is active, or when a post-charge phase is active.
9. – Bluetooth Wireless Connectivity
See Android and Apple I-Phone links to ChargerConnect App above.