How To Wire Your New Lester Summit Series II Golf Cart Battery Charger – 650W
How To Wire Your New Lester Summit Series II Golf Cart Battery Charger – 650W
This is a quick resource for those going it alone and putting their new Lester Summit Series II Golf Cart Battery Charger into service. These units are very well designed and very universal. Works great in all applications though some configuring is required.
Unfortunately for us Lester has followed the trend of other large companies and does not include multi-page owners manuals in their products any longer. This is a good idea I am sure for the forest and environment but not going to help me the installer with the task at hand. So they opt for electronic files and expect you to find one online some where as we have this blog post. Though we get alot of calls concerning this issue so we just made it easier for you to access the information you will need to wire up your new golf cart battery charger.
Note:These wiring instructions will only apply to the 650W version of this charger. If you purchased 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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Make sure you ordered and received the correct charger and DC side cord set for your application. ref to the DC side cord set legend below. Or double check the golf cart charger receptacle on your golf cart if you intend to use this charger in an Off-board application. Otherwise it is pretty straight forward to install and use in an onboard application. All onboard applications will simply require a ring terminal DC cordset to wire to the main positive and negative terminals on the battery bank in their application.
1. – Charger Mounting Recommendations
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. The best mounting orientations for this charger are shown below in Figure 2-1. The best way to mount the charger for On-board use is with the charger base bolted to a 0.1 inch (2.5 mm) minimum thick metal plate. This provides both a strong base but good thermal conductive cooling. A poor thermal conductive material is plastic or wood though charger should still perform well. We have installed many of these units in many applications and to date no issues!
The charger dimensions and mounting hole locations are shown 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 cordsets when they need to be routed to the opposite ends as shown in Figure 2-3.
2. – How To Route AC and DC Side Battery Charger Cordset Properly For Your Application
Depending on the application ( On-board vs Off-board) will determine the proper way to route the cord sets for optimal fit, function and performance. The Lester Summit II Series Chargers are designed very well and the designers thought of it all as they created the next generation golf cart battery charger to meet or exceed your needs. With a combination of molded track into the cooling fins of the charger or with additional support and routing hardware you can wire up in a few configurations. See Figure 2-3 below.
3. – OFF-BOARD (SHELF) VERSUS ON-BOARD (BUILT-IN) CHARGERS
This section describes how the charger operates when the charger type is set to Off-Board or On-Board. Based on your application, this setting can be changed via the ChargerConnect app under “System Profile” (Learn More About the App Now – Then Tap To Get the App).
The charger was factory-configured with the active battery profile that was requested as part of the original order from Lester Electrical. The charger was also factory-configured for mounting on-board a battery powered vehicle/machine or for off-board use in a shelf or portable application per the original order from Lester Electrical. Before (1) using the charger for the first time or (2) using the charger with a battery pack of a different type or capacity, use the ChargerConnect app to verify that the proper active battery profile is selected and that the system settings match your application. (Lester Summit II Series Battery Chargers Battery Profile Quick Reference).Off-Board Applications
Off-board chargers are designed to be used in shelf or portable applications. 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. Disconnecting the DC output from the battery pack IS REQUIRED to automatically start a new charge cycle.
On-board chargers are designed to be mounted on electric vehicles/equipment. 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.
4. – Battery Chemistry and Types
Battery Type – These charger contain multiple battery profiles for different battery types (including wet/flooded, AGM, and gel) and capacities of batteries. If you purchased your new Summit Series II Golf Cart Battery Charger from us the charger is set for basic flooded batteries. They are always factory-configured with the active battery profile that is requested as part of PO to Lester Electrical.
It is still recommended that you use the ChargerConnect app to verify the proper active battery profile is selected. (A) Before using the charger for the first time or (B) using the charger with a battery pack of a different chemistry or capacity. If the proper battery profile is not available on the charger, the ChargerConnect app can be used to download the appropriate battery profile from the Cloud. If the battery type you will be charging is not available via the ChargerConnect app Cloud.
(For example, If you need information for a specific lithium ion brand or chemistry),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 the active battery profile is changed, 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. Water electrolyzed by discharging and charging the battery is replaced through these openings. Sealed (AGM and gel) 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 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 is designed to operate at 50-60 hertz, with an AC input rating of 100-240 volts, single-phase. The charger has an AC operating range of 85-265 volts, 45-65 hertz. This golf cart battery charger is equipped with an IEC 60320 C16 inlet for the AC input power as shown below. This allows the AC power cord set to be selected 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 included to retain the AC power cord in the IEC connector.
Special Note – Those who require an extension cord. Strive to make the distance as short as possible and use the biggest thickest industrial cord you have handy. This is because you will experience voltage drop over a longer span (cord) 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.
The installed AC power cord set must be plugged into an outlet that is properly installed and grounded in accordance with all applicable electrical codes and ordinances. If this charger includes the UL Listed symbol on its ratings label, it is provided 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 charger 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
If you still have not connected to your charger or downloaded the ChargerConnect App for your new Lester Summit II Battery Charger Scroll back up in this How To Article until you see the Get Connected Links for Android and iPhone applications.