Legacy® Insight™ Battery Charger Service Manual
Contents
1. 16 Configuration 16 nine le tien 16 Auto Manu Capacity 16 Capacity eis 16 Temperature 17 High 17 Charge et 17 Profile iret en A 17 Charge 17 Condition 18 Float 18 Maximum Current 18 Equalization 18 Manu Current 18 hdd PR nt en bees 18 Delayed 18 Frequency ss 18 entame 18 Network 18 OPTION xc Ra At 19 Electrovalve Time 19 Rst Memo Status 19 Parameters 20 Date Time 20 Daylight 5 20 20 20 CODI aS ndi 20 Change Password 20 Password eene 20 Information 20 Charging the Battery 21 Charger Idle Display 21 Delayed 21 Starting a Charge2. V FLOOR CHARGER LARGE CONFIGURATION COMPONENT LOCATIONS Bridge MOV Bridge Rectifier 090 6LA20403 090 6LA20436 AC Fuse Block Resonant Capacitors AC Fuse Power Transformer Resonant Choke EE imt _ EN EIE Ce 090 6L10158 Diodes 2 3 E E N a 4 E 14 a gt Saws a Shunt a TI c o IGBT IGBT MOV P a m i Cooling Fan Snubber Capacitor 40 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 10uF Capacitors Line Choke 090 11 3 Bleeder Resistor M Board Control Board 090 11 1 090 1 1 2 FLOOR CHARGER SMALL CONFIGURATION COMPONENT LOCATIONS Bridge MOV Bridge Rectifier 090 11 4 090 6L20135 AC Fuse Block E A Resonant Capacitors Power Transformer Resonant Choke 090 6L10158 Diodes Diode Suppressor 00 O 2 gt a 13 2 5 TI e Li Cooling Fan 090 11 5 IGBT MOV Snubber Capacitor 41 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 N A FOR CEC CHARGERS SCHEMATIC 2 5 Electrov 220Vac SUPPLY 6 MAIN BOARD 81 5H SH Vbatt EV ST1 42 DOUGLAS BATTERY 1255 Creekshire Way Suite 221 Winston Salem NC ISO 9000 27103 1 800 DOUGLAS 1 800 368 4527 www dougl
3. Status Information Total number of charges Corresponds to the total of normally terminated charges and charges terminated with or by faults CELS Number of charges terminated abnormally CEST Number of charges normally terminated EGAL Number of equalization charges completed by the charger TH Number of charger temperature faults DF1 etc Number of faults recorded by the charger see Fault Codes Charge The Memorizations can be cleared via the Reset command in the Configuration Menu Password required Legacy Insight Service Manual 1 1621 Rev A 6 10 14 This menu provides access to the USB function The charger can store charging data in a USB memory Password is required to view this menu Record Memo Enables the storage of charge Memorizations and the Status data to a USB data storage device aka memory stick thumb drive To record memos Insert the data storage device in the USB port on the side of the charger Go to Main Menu gt USB gt Record Memo Select Display will show Record MemoxX 1 2 3 4 When finished charger will return to idle state Remove data storage device from USB port The file in CSV format useable with Memoreport or Excel will be stored in the data storage device under the name MDDDHHMM CSV where M is for Memorization data file DDD Day of the year HH Hour of file creation MM Minute of file creation GLE
4. X1060 X1060 X127 6LA10659 X127 6L10655 X127 6LA10678 X127 6L10643 X127 6L10644 X127 6L10648 X127 6L10649 X127 6LA15252 X127 6LA15262 X014 99 8 X014 99 10 X014 99 12 X014 99 15 X014 99 20 X014 99 25 X014 99 30 X014 99 35 X014 99 40 X014 99 50 X014 33 3 X014 6L10466 X117 150 50 X117 6L10326 X117 6LA18620 Description Display Board 208V Power Board 240V Power Board 480V Power Board 600V Power Board Power Transformer Power Transformer Power Transformer Power Transformer Power Transformer Power Transformer Power Transformer Power Transformer Power Transformer 8A AC Fuse 10A AC Fuse 12A AC Fuse 15A AC Fuse 20A AC Fuse 25A AC Fuse 30A AC Fuse 35A AC Fuse 40A AC Fuse 50A AC Fuse 160A DC Fuse 315A DC Fuse 150A Shunt 250A Shunt 300A Shunt REPLACEMENT PARTS and QUANTITY s Euge 554 2 2 5 3 8 5 9 5 8 41414 04141414 410216 6 lol 11111111 1 4 111411 111 1114 11111111 1 11141111 141111 1 11111111 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 de 621 1 1 1 1 1 1 1 1141 1 1 1 1 1 1 1 1 111 111 1 1 1 1 1 111 111 1 111 111 111 1 1 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 1 11 1 111411 1 11 1 11 1 41 1 1 1 1 4T 1 1 1 1 1 PERS 1 4 1111111111111
5. 3 78 437 64 17 23 31 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 EXTERIOR FLOOR CABINET DIMENSIONS AND PARTS Top P N X052 99 3 12B 29 Left Side P N X057 99 0 7 Door P N X054 99 3 17B Back P N X057 99 3 16B 24 00 32 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 TECHNICAL SPECIFICATIONS KW Output AC Input DC Output Max 8 hour Charger Voltage Codes Voltage Max Phase Cells Max Current Capacity Ah Cable Amps A AWG 4 1T 208 12 4 3 12 18 24 85 80 70 530 500 400 2 4 1W 240 11 4 3 12 18 24 85 80 70 530 500 400 2 4 1Y 480 5 7 3 12 18 24 85 80 70 530 500 400 2 4 1C 600 4 3 3 12 18 24 85 80 70 530 500 400 2 4 3T 208 12 6 3 6 12 18 100 100 95 625 625 595 2 4 3W 240 11 0 3 6 12 18 100
6. 4129 Delayed Start If the charger was programmed for delayed start Configuration gt Charge gt Delay charging will begin following that delay When the battery is plugged in to the charger the display shows the time remaining before the programmed charging starts 20 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 Starting a Charge cycle The charger will start automatically when a battery is connected or push the Stop Start button if the battery is already connected Effective charging starts after a 20 second countdown The charger uses Profile Capacity and Temperature settings programmed in the Configuration menu Effective charge A few moments into the effective charge the display will begin alternating between the following charging information 1 10kW 24a CHARGE 7 210A 50 3V 4 Olapr11 5 Ref Description 1 Charger type 2 Firmware version 3 Charger status CHARGE AVAIL EQUAL FAULT 4 Selected charge profile 5 Programmed battery parameters Cap temp 6 System time and date if set 7 Charger output current Alternating battery charge statistics Batt V Vpc Ah 8 returned time on charge estimated time remaining State of Charge 21 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 End of charge without equalization The green complete LED comes on after proper end of charge The green
7. 6 10 14 3 DC OUTPUT FUSE Schematic symbol F3 Disconnect the AC power and the battery before opening the door The checking of output fuse F3 is carried out with the multimeter in Q position F3 Ok Infinity replace 4 OUTPUT DIODES Schematic symbol G3 G4 G5 G6 Disconnect the AC power and the battery before opening the charger door This check is carried out with a multimeter in Diode Check position If the indication is 0 3V in one direction and Open in the other all diodes are OK If one of the diodes is short circuited the measurement will be 0 0V in both directions Disconnect the wires from the secondary of power transformer TM to isolate the defective diodes one by one and identify the damaged one by repeating the steps above on each diode VDC 0 3 V all diode OK VDC 0 0 V isolate and replace per instructions above DIODE CONNECTION TIGHTENING TORQUE When a copper bar is present 11in Ib THERMAL GREASE IS REQUIRED ON THE HEATSINK 26 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 5 FANS THERMAL FAULT Schematic symbol EV1 EV2 EV3 some models Set the multimeter to position VAC Turn on the charger AC power supply battery connected Open the door and carefully measure the fan voltage To check fan coil disconnect the AC power and the battery then disconnect one lead of the fan coil You should measure between 500
8. 029 6LA13000 Res Capacitor 2 1 2 1 2 029 6LA13001 Res Capacitor 2 1 1 2 029 6L13099 Res Capacitor 2 1 1 029 6L13104 10uF Capacitor 412 2 21 114 2 2 2 4 2 2 214 2 2 2 4 4 4 4 4 14 4 4 4 4 4 4 4 36 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 REPLACEMENT PARTS and QUANTITY 5 81518 5 2 54 5 8 5181 5 21518 5 8 5 4 3 8 5 38151 58 Part Number Description l l ll ll 4151 X020 6L 3 AC Power Line Filter 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X020 6L 4 AC Power Line Filter 1 1 1 1 1 1 1 1 1 126 EQ3 1 Display Ribbon Cable 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X026 60 1 Control BD Ret Clip 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X1106 99 PT23 Current Sensor 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 438 326 2 Cooling Fan 3 2 21213 2 212 3 212 2 3 2 2 2 3 3 3 3 3 3 3 3 3 3 3 3 3 225 019 10 5 8kW to 15kW Cover 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 225 019 6 4kW to 6kW Cover 1 1 1 1 1 1 1 1 1 1 1 1 X002 6L10721 85 Degree Thermostat 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X015 50 2 30A Fuse Holder 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X015 50 4 60A Fuse Holder 1 1 1 1 1 X1106 99 3 7 Shunt MOV Assembly 1 1 1 1 1 1 1 1 1 1 1 1 1
9. Connection 7 Plug Polarity sss 7 Grounding the Charger 7 Description of Operation 8 eric 8 Beginning the Charge 8 Gh atglng ene e atten entes 8 AC Power Fail sese 8 Series Charging 8 1055 2 55 522 442 4 224 43424142 212 42 440 9 Bon ted dette Nis Reece 9 Charging Coefficient 9 Compensation Charging 9 Charging Profile 9 Cold Storage 9 Equalization Charging 9 ciae 9 loriic Profile inserer inscrite 9 OPPOR Profile 10 Power 10 Refresh 10 Power 10 Rest Function 10 CEG Aa ed TERR desee 10 Operating Instructions 11 Wall Charger Control Panel 12 Floor Charger Control Panel 13 Menu Access een 14 Main 14 2 14 DD 15 Record Memo 16 Update Software
10. Cycle 22 Effective Charge 22 End of Charge w o Equalize 23 End of Charge with Equalize 23 Fault Codes 24 Maintenance amp Service 25 Testing of Components 26 Component Replacement 29 Wall Mounting Dimensions 30 Exterior Wall Cabinet Dimensions 31 Floor Mounting Dimensions 32 Exterior Floor Cabinet Dimensions 33 Technical Specifications 34 Replacement Parts 35 Component Locations 39 5 5 2 52444 52444 22 nn 43 Mounting the Wi iQ Adapter 44 Wi iQ Communications Setup 45 I B 1621 Rev A 6 10 14 Legacy Insight Service Manual 1 1621 Rev A 6 10 14 AC LINE VOLTAGE LETTER CODES The following table describes the code letters to be used in new charger part numbers to indicate the AC line voltage s and AC line frequency at which the charger can be operated Line SUE Voltage s Frequency Comments Letters volts rms Hertz C 600 50 60 600 VAC only AC power line filter X020 6L 4 Y 480 50 60 480 VAC only AC power line filter X020 6L 3 W 240 50 60 240 VAC only AC power line filter X020 6L 3 T 2
11. Frequency Selects one or several periods for carrying out the equalization charge The user can select one or several days per week Cable Length Select the length of DC cables from the charger to the battery terminals in 1 foot increments from 3 to 99 ft 1 to 30 m Section Sets the DC cable gauge Selections are 8 6 4 2 1 0 2 0 3 0 4 0 AWG 10 16 25 35 50 70 95 or 120 mm Network Option Set a protocol and configure the charge for the connecting the charger to a network JBUS Used only by the factory Ethernet Settings include P Address DNS Gateway Subnet Mask DHCP OFF ON Speed The values for these settings will depend on the specific application and should be obtained from a network administrator for the network being used Option Options Test Turns on Battery Status Red Green and Electrovalve output briefly to test operation 17 Legacy Insight Service Manual 1 1621 Rev A 6 10 14 Rst Memo Status Resets and clears all memorizations and status history WARNING ONCE THE MEMORIZATIONS AND STATUS HAVE BEEN CLEARED THEY CANNOT BE RECOVERED Legacy Insight Service Manual 1 1621 Rev A 6 10 14 Parameters Date Time Sets date and time of the charger The clock has a battery backup which will preserve the time when power to the charger is off Daylight Savings Enable or disable automatic clock adjustment for daylight savings time When enabled time will move ahe
12. and 600 Ohms across the coil terminals 230 VAC 230 VAC voltage Fan s Action Present Working Refer to Test 8 Present Not working Replace the non working fan s Replace the A3 main board or Not present Not woring control transformer 6 THERMOSTAT THERMAL FAULT Schematic symbol ST1 Disconnect the AC power and the battery before opening the charger door Thermostat ST1 is tested with a multimeter set to the Q position 0 5 1 Ok Infinity replace ST1 27 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 COMPONENT REPLACEMENT IMPORTANT Disconnect battery and turn AC power OFF before servicing IGBT BRIDGE RECTIFIER or DIODE Replacement on Aluminum heatsink REMOVAL IGBT Remove MOV snubber caps and unscrew the buss bars from the IGBT leaving them attached to the capacitors on top Remove the IGBT by removing the 4 mounting screws and sliding it from under the buss bars If the same wire harness is to be used you need to unsolder the wires and resistors from the damaged IGBT and solder them back to the new IGBT in the same way Make notes or take a picture that will help you in the process BRIDGE RECTIFIER Remove MOV suppressor assembly AC wires coming from the fuse block or line filter if installed and wires going to the DC choke and filter capacitors Remove the 2 mounting screws the bridge should come off DIODE Remove DC fuse and the long bus
13. at a different frequency or from a generator with unstable frequency Phase Number 3 indicates a Three Phase Charger DC Volts This gives the nominal DC output voltage of the system Rated DC Amps This is the nominal DC value of current that this unit will deliver to a battery that is 100 discharged CEC This logo is applied to chargers that are certified by California Energy Commission Legacy Insight Service Manual 1 1621 Rev A 6 10 14 INSTALLATION WARNING The shipping pallet must be removed for proper and safe operation Location For maximum trouble free service choose a location which is free of excess moisture dust and corrosive fumes Also avoid locations where temperatures are high or where liquids will drip on the charger Do not obstruct the ventilating openings or the space under the charger Mounting Wall Cabinet Chargers The charger must be mounted on a wall or stand in a vertical position The lower part of the charger must be at least 24 from the ground and or the charger below and the upper part 36 from the ceiling The minimum distance between two chargers must be12 The charger will be installed with four 5 16 bolts or with the bracket supplied See the Wall Mounting Dimensions section at the end of this manual for proper bolt pattern Placing Floor Cabinet Chargers Allow at least six 6 inches of clearance at rear and sides of the charger for air circulation Stack
14. the battery Automatic start If an equalization day has been programmed Configuration gt Equalization gt Frequency the equalization charge will start automatically on the programmed day of the week after charging is complete The battery will be available when the green LED comes back on and the display shows AVAIL The battery is now ready for use If the battery remains plugged in and refresh charge has been enabled refreshes will occur to maintain an optimal charge Push the ON OFF button before unplugging the battery 22 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 Fault Codes In case of a fault one of the corresponding fault codes listed below will appear on the display If it is a critical fault charging will stop and the red Fault LED will be illuminated Fault Critical Cause Solution DF1 Yes Low output current Check input voltage and fuses Check for proper battery connection uin wee OuIpubraull reversed polarity Check output fuse Battery voltage too high gt 2 3 Vpc or DF3 Yes Improper battery too low lt 1 6 Vpc Use proper charger for battery The battery has been Prevent future over discharging of DF4 No discharged more than 8096 battery Battery charge gauges and lift of its capacity interrupts may need calibration Non critical fault Check battery cables DF5 No Battery requires inspection for condition and size check for loose connect
15. usine peut entretenir cet quipement Pour le service veuillez contacter la soci t EnerSys ou l un de ces repr sentant 1 800 251 6560 Avant toute intervention d entretien ou de r paration il faut s assurer que le chargeur est hors tension et la batterie est d connect e Le chargeur n est pas pour un usage ext rieur Ne pas exposer le chargeur l humidit Les conditions de fonctionnement devraient tre 15 40 c humidit relative de 0 de 70 Ne pas mettre en fonctionnement le chargeur s il a recu un choc m canique ou tout autre dommage di quel que fa on Pour une protection permanente et pour r duire le risque du feu installez les chargeurs sur un plancher ou un mat riel non combustible tel qu un mur plein en b ton en brique ou l acier Legacy Insight Service Manual I B 1621 Rev A 6 10 14 TECHNICAL INFORMATION The nameplate located on the outside of the charger should be used to check this application before installation SALES N Part Number MODEL NET This number specifies in general the characteristics of this particular part lt j charger and for this reason it is required in any discussion 17 correspondence regarding this unit BATTERY LI3C F 10 241YO AMP HOURS Model gt NO Phase CHARGE CEC Floor Cabinet W wall cabinet Power Level Max Numbe
16. wide range of capacities The charging coefficient is maintained absolutely on all types of batteries Legacy Insight chargers adapt to the battery s capacity and its discharge level Legacy Insight chargers can easily be set to charge flooded batteries used in cold or freezer storage applications ionic or opportunity profiles This battery charger is also designed to charge flooded and sealed lead acid storage batteries within the range of the cell and ampere hour rating as marked on the nameplate Beginning the Charge When a battery is connected to the charger the control board senses voltage and after a 20 second delay the charger energizes Charging Charging current is determined by the battery voltage and interaction of the charger Charging current declines automatically as battery voltage rises during the charge As the battery charges the LCD display will output various charge parameters including the percentage of battery capacity AC Power Fail If the AC power fails with a battery connected to the charger during a charge cycle the charger will reset and start a new charge cycle when power is restored All charger settings as well as the time and date are preserved Series Charging In series charging the voltages of both batteries add up and must match charger s nameplate rating The charger s ampere hour rating must be equal to each of the batteries ampere hour rating Charge cycle will not start unless b
17. 08 50 60 208 VAC only AC power line filter X020 6L 3 SPECIALTY CHARGER OPTIONS LIST Suffix Description C6 6 of 10AWG AC Cord with 30 AMP Plug C10 10 of 10AWG AC Cord with 30 AMP Plug C12 12 of 10AWG AC Cord with 30 AMP Plug C8 8 of 10AWG AC Cord with 30 AMP Plug CF 10 of 8AWG AC Cord with 50 AMP Plug CF12 12 of 8AWG AC Cord with 50 AMP Plug 6 of 10AWG AC Cord with 30 AMP Plug and 30AMP receptacle L10 10 of DC cable L13 13 of DC cable L15 15 of DC cable L18 18 of DC cable L20 20 of DC cable L25 25 of DC cable L30 30 of DC cable NC No DC cables NOT UL APPROVED Charger shipped a Plastic Pallet S Series DC Cables Reference page 33 Technical Specs for charger cable sizes Legacy Insight Service Manual 1 1621 Rev A 6 10 14 8 9 10 11 IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety and operating instructions Before using the battery charger read all instructions cautions and warnings on the battery charger the battery and the product using the battery This charger has been designed to only charge flooded lead acid batteries Read and understand all setup and operating instructions before using the battery charger to prevent damage to the battery and to the charger Do not touch non insulated parts of the output connector or the battery t
18. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X1106 99 3 8 IGBT MOV Assembly 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 23 IGBT MOV Assembly 2 2 2 2 2 2 2 2 2 X1106 99 3 9 Bridge MOV Assembly 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 rd Bridge MOV Assembly 111 1 1 006 201 11 Insulated Standoff 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 2 3 3 3 033 406 30 M6x30mm Socket Set Screw for Insulated 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 2 3 3 3 X1060 06 HFR 1 Bleeder Resistor Board 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 X1106 99 3 13 Output Diode Suppressor 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 X002 LTI3 1 LTI3 W Wall Keypad 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X002 LTI3 2 LTI3 F Floor Keypad 4 1 32085451 425 roe eie eoo Pent ose esee Je Loo ee 4 8 4 2 Fed X039 IQ 11C USB Port Assembly 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 126 IQ 1 1 USB Patch Cable 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ghee dam 8 00 215552 4 RES 012002 54 e 50126481 20114 Remote control can only be used on remote control ready chargers Retrofit kit P N X225 RCK 7 is used for chargers not factory equipped with the remote control ready option 37 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 LARGE WALL CHAR
19. 100 95 625 625 595 2 4 3Y 480 5 5 3 6 12 18 100 100 95 625 625 595 2 4 3C 600 4 4 3 6 12 18 100 100 95 625 625 595 2 6 1T 208 18 5 3 12 18 24 110 110 105 690 690 655 2 6 1W 240 17 0 3 12 18 24 110 110 105 690 690 655 2 6 1Y 480 8 5 3 12 18 24 110 110 105 690 690 655 2 6 1C 600 6 4 3 12 18 24 110 110 105 690 690 655 2 6 3T 208 18 5 3 6 12 18 140 140 140 875 875 875 1 0 6 3W 240 17 0 3 6 12 18 140 140 140 875 875 875 1 0 6 3Y 480 8 5 3 6 12 18 140 140 140 875 875 875 1 0 6 3C 600 6 4 3 6 12 18 140 140 140 875 875 875 1 0 8 1T 208 24 7 3 12 18 24 150 150 140 940 940 875 1 0 8 1W 240 22 8 3 12 18 24 150 150 140 940 940 875 1 0 8 1Y 480 11 4 3 12 18 24 150 150 140 940 940 875 1 0 8 1C 600 8 5 3 12 18 24 150 150 140 940 940 875 1 0 10 1W 240 27 5 3 12 18 24 200 200 180 1250 1250 1125 3 0 10 1Y 480 15 0 3 12 18 24 240 240 180 1500 1500 1125 3 0 10 1C 600 11 0 3 12 18 24 240 240 180 1500 1500 1125 3 0 10 2Y 480 15 0 3 24 36 40 120 115 110 750 720 690 2 10 2C 600 11 2 3 24 36 40 120 120 110 750 750 685 2 15 1Y 480 20 5 3 12 18 24 260 260 250 1625 1625 1565 4 0 15 1C 600 15 3 3 12 18 24 260 260 250 1625 1625 1565 4 0 15 2Y 480 21 5 3 24 36 40 170 170 160 1065 1065 1000 2 0 15 2C 600 16 3 3 24 36 40 170 170 160 1050 1050 1000 1 0 LTI3 W wall mount chargers have a maximum cable gauge of 3 0 AWG 33 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 P
20. 1111111 1 1 1111111111 1 111 1 111 35 Legacy Insight Service Manual 1 1621 Rev A 6 10 14 REPLACEMENT PARTS and QUANTITY 518 5 4 5 2 5 4 5 2 514 50 8 Part Number Description ss ls 41414 R507 6LA14008 Output Diode 2 21 21 21 21 21 21 21 121 121 21 121 12121 2121 141 41 4 4 4 4 4 4 R507 6L14028 Output Diode 4 4 4 4 4 R507 6L14022 Bridge Rectifier 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X020 6L18616 Line Choke 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X020 6L10310 Line Choke 1 1 1 1 1 1 1 1 1 1 1 1 X020 6LA10334 Resonant Choke 1 1 1 1 1 1 1 X020 6LA10323 Resonant Choke 1 1 1 1 1 1 1 1 X020 6LA18621 Resonant Choke 1 1 1 1 1 X020 6L10353 Resonant Choke 2 2 2 2 2 X020 6LA18614 Resonant Choke 2 2 X020 10 1 Resonant Choke 1 X020 10 2 Resonant Choke 1 X225 1Q 200 600 IGBT Kit 1 1 1 1 1 1 1 1 1 1 1 X225 IQ 6L19610 IGBT Kit 1 1 1 1 1 1 1 1 X225 1Q 200 1700 IGBT Kit 1 1 1 1 1 1 1 1 1 X225 IQ 6LA19617 IGBT Kit 1 029 101 Snubber Capacitor 212 2 212141412 4 4 029 6LA13170 Snubber Capacitor 2 2 2 2 2 2 2 2 029 6LA13182 Snubber Capacitor 2 2 2 2 029 6LA13183 Snubber Capacitor 2 2 2 2 2 2 2 X020 6LA18624 Output Choke 1 1 111 029 6LA13000 Res Capacitor 1 1 2 11 212 2 1 211 212 2 1 213 029 6LA13001 Res Capacitor 1 2 2 2 2 413 3 4131313 1 2 029 61 13099 Res Capacitor 1 3
21. ART button Select menu items Enter values Stop and restart battery charge 4 Navigate RIGHT EQUALIZE button Scroll right Start equalize or desulfation 5 Navigation DOWN button Navigate menus Change values 6 Navigation LEFT ESC button Enter Main Menu Scroll left Exit menus 7 RED fault indicator OFF no fault FLASHING ongoing fault detected ON fault 8 YELLOW charging indicator OFF charger output is off ON charging in progress 9 GREEN charge complete indicator OFF charger off or battery not available Flashing cooling phase ON battery ready and available 12 Legacy Insight Service Manual 1 1621 Rev A 6 10 14 When the charger is idle press and hold lt ESC gt the Main Menu is then displayed The current menu is automatically exited after six minutes of inactivity or can be exited voluntarily by pressing the lt ESC gt button The menus provide access to the following functions e Last 896 charging cycles MEMORIZATIONS menu Viewing of faults alarms etc STATUS menu Download of data stored in the charger via the USB storage memory Charger configuration CONFIGURATION menu Setting of date language and others PARAMETERS menu Management of password PASSWORD menu Viewing basic charger information INFORMATION menu Main Menu All menus are accessed from Main Menu a detailed description of each menu is included in the next sections of this manu
22. DOUGLAS LEGACY INSIGHT Model Standard LI3 amp LI3C CEC Legacy Insight Battery Charger Service Manual 1621 Rev A 6 10 14 IMPORTANT Read and understand your user s manual before installing operating or servicing this product DO NOT DESTROY THIS BOOK Legacy Insight Service Manual TABLE OF CONTENTS AC Line Voltage Letter Codes 2 Specialty Charger Option List 2 Important Safety Instructions 3 Technical Information 4 Part Number 4 Serial Number 22 2220422 4 Battery 4 Ampere Hours eene 4 GEIS 3 4 Input AC Volts sss 4 Input AC 4 La PA eee CER 5 tide Ed 5 5 Rated DC 5 GEG Unus mut en 5 Installation 6 6 Mounting Wall Chargers 6 Placing Floor Cabinet Chargers 6 Stacking Multiple Chargers 6 Electrical Connections 7 On three phase units 7 Connecting Input Power 7 AC
23. GER COMPONENT LOCATIONS AC Fuse Block Display Board Keypad Line Choke 10uF Capacitors Power Board Bleeder Resistor Board Current Sensor Bridge Rectifier Bridge MOV im eaten 9 Im 1 O seen 090 6LA2031 1 090 6LA20403 eo c Jm 5 a Resonant Capacitors 090 6LA20309 090 6LA20308 Power Transformer 3 2 Diodes Shunt IGBT Snubber Capacitor g O TI c o IGBT MOV Legacy Insight Service Manual I B 1621 Rev A 6 10 14 SMALL WALL CHARGER COMPONENT LOCATIONS AC Fuse Block Display Board Keypad AC Power Line Filter Bridge MOV Bridge Rectifier LI Power Board 090 11 4 090 11 3 10uF Capacitors Current Sensor Bleeder Resistor Board 090 11 1 090 11 2 Control Board Thermostat Cooling Fan Ki T B VES CEST B vou AS b Resonant Choke 090 6L20135 Line Choke Resonant Capacitors Power Transformer 090 6L10158 Diode Suppressor Diodes Li Shunt DC Fuse 090 11 6 IGBT Snubber Capacitor IGBT MOV 39 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 10uF Capacitors Line Choke Power Board 090 6LA2031 1 Current Sensor Bleeder Resistor Board Diode Suppressor Control Board 090 6LA20308 090 6LA20309 090 6L20042 090 6LA20311 TU
24. ad on hour at 02 00 on the second Sunday in March and will move back one hour at 02 00 on the first Sunday of November The charger must be powered up at the time of the change for it to take effect Language Selects the language displayed in the menus French English German and Italian Region Select the format for date metric EU or imperial US units for temperature length and cable gauge Contrast Modifies the display contrast level 40 to 49 Change Password Password required to view this menu Change the password to any 4 digit code Password This is where the password is entered to gain access to protected menus such as USB and Configuration Default password is 0099 View information about the charger such as firmware version and charger type Legacy Insight Service Manual 1 1621 Rev A 6 10 14 Charging the Batte At this point the charger should have been set up by a qualified service person Charging can only begin with a battery of the proper type capacity and voltage connected to the charger Charger Idle Display With the charger in wait mode No battery connected and without pressing the Stop Start button the display will show the following information 1 10kW 24a 2 4 01 11 6 p Description Charger type Firmware version CONNect Battery Selected charge profile Programmed battery parameters Cap temp System time and date oo
25. al The menus that require a password are not displayed until the correct password has been entered Memo Status USB password Configuration password Parameters Information Password Memorizations The charger can display the details of the last 896 charge cycles Memorization Access On the Main Menu select Memo and press lt Enter gt Memorizations Display Screen The display shows here the charges have been stored in memory title line MEMO 1 is the latest charge memorized After memorizing the two hundredth charge the oldest record is deleted and replaced by the next oldest 5 08 01 200 4 28 01 200 6 68761726 7 687617266 9 9 26 C 17 29 17 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 Displaying a charge cycle Proceed as follows 1 Select a record MEMO x using the A buttons 2 Display the first History screen by pressing Enter 3 Display the second History screen by pressing V 4 Return to the Main Menu by pressing Esc The charge history is displayed use the A to scroll through the parameters The Memorizations can be cleared via the Reset command in the Configuration Menu Password required This menu displays the status of the charger s internal counters number of normal and equalize charges faults by type etc Access On the Main Menu select Status and then press Enter STATUS SCREEN 1
26. ard was in REPLACEMENT 1 Align the board mounting holes to the standoffs and carefully push the board in until it locks to the standoffs 2 Carefully attach the connectors back to the replacement board 3 Match dip switches to the old board 4 f Cold Storage selected match battery capacity to charger as explained under section Changing Setting 28 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 WALL MOUNTING DIMENSIONS 85 0 2250 19 133501 WALL SUPPORT BRACKET P N 159 6LA20319 SLOT CENTERS 3 8 HARDWARE IS RECOMMENDED DIMENSIONS SHOWN IN THE DRAWING TO THE LEFT ARE FOR WALL MOUNTING THE CHARGER AND ARE ACCURATE FOR BOTH THE LARGE AND SMALL WALL MODELS AS LONG AS THE MEASUREMENTS ARE TAKEN FROM THE BOTTOM OF THE CABINET S BASE O39 10 TYP 21 26 REF 390 15 35 29 Legacy Insight Service Manual 1 1621 Rev A 6 10 14 EXTERIOR WALL CABINET DIMENSIONS AND PARTS 009 IQ 1 29 72 Kit P N 225 019 10 5 Kit P N X225 019 IQ 6 Includes sheet metal Includes sheet metal and plastic parts and plastic parts shipped in a box fully shipped in a box fully assembled assembled e 14 59 57 1 13 1 009 IQ 1 X057 LTI3 2 30 Legacy Insight Service Manual 1 1621 Rev A 6 10 14 FLOOR MOUNTING DIMENSIONS 96 01
27. art Number X1060 IQ4 1T3 X1060 IQ4 1W3 X1060 IQ4 1Y3 X1060 IQ4 1C3 X1060 IQ4 3T3 X1060 IQ4 3W3 X1060 IQ4 3Y3 X1060 IQ4 3C3 X1060 IQ6 1T3 X1060 IQ6 1W3 X1060 1Q6 1Y3 1060 06 1 3 X1060 IQ6 3T3 X1060 IQ6 3W3 X1060 IQ6 3Y3 X1060 IQ6 3C3 X1060 IQ8 1T3 X1060 IQ8 1W3 X1060 1Q8 1Y3 X1060 1Q8 1C3 X1060 1Q10 1W3 X1060 1Q10 1Y3 X1060 1Q10 2Y3 X1060 1Q10 1C3 X1060 IQ10 2C3 X1060 1Q15 1Y3 X1060 1Q15 1C3 X1060 1Q15 2Y3 X1060 1Q15 2C3 Description Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board Control Board REPLACEMENT PARTS and QUANTITY 4 1W 4 1Y 4 1C 4 3 4 3W 4 3Y 4 3C 6 1T 6 1W 6 1Y 6 1C 6 3T 6 3W 6 3Y 6 3C 8 1T 8 1W 8 1Y 8 1C 10 1W 10 1Y 10 2Y 10 1C 10 2C 15 1Y 15 1C 15 2Y 15 2C 4 1T 34 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 Part Number X026 EQ3 1 X1060 12 SB208 X1060
28. asbattery com 1621 Rev A 4 13 2013 EnerSys Delaware Inc d b a Douglas Battery All Rights Reserved Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted
29. complete LED is on and the display shows AVAIL The display alternates between e Total charging time Amp hrs restored to the battery Any other lit LED indicates a problem during charging Please refer to paragraph Control Panel for more information If the battery remains plugged in and refresh charge has been enabled refreshes will occur to maintain an optimal charge The battery is now ready for use Push the ON OFF button before unplugging the battery End of charge with equalization An Equalize charge can be started manually or automatically Manual Start 1 At the end of charge green LED on or flashing press on the lt EQUALIZE gt button The equalize button can also be pressed any time during the charge and an equalize charge will be started after charging is complete NOTE When an equalize is manually started the output current will be set to the value saved in Configuration gt Equalize gt Manu Current 2 The start of the equalization charge is indicated by the message EQUAL During the equalization charge the charger displays the output current and alternating the battery voltage voltage per cell remaining time 3 The battery will be available when the green LED comes back on and the display shows AVAIL 4 The battery is now ready for use If the battery remains plugged in and refresh charge has been enabled refreshes will occur to maintain an optimal charge Push the ON OFF button before unplugging
30. erminals to prevent electrical shock During charge batteries produce hydrogen gas which can explode if ignited Never smoke use an open flame or create sparks in the vicinity of the battery Ventilate well when the battery is in an enclosed space Do not connect or disconnect the battery plug while the charger is on Doing so will cause arcing and burning of the connector resulting in charger damage or battery explosion Lead acid batteries contain sulfuric acid which causes burns Do not get in eyes on skin or on clothing In cases of contact with eyes flush immediately with clean water for 15 minutes Seek medical attention immediately Only factory qualified personnel can service this equipment De energize all AC and DC power connections before servicing the charger The charger is not for outdoor use Do not expose the charger to moisture Operating conditions should be 0 to 104 F 0 to 70 relative humidity Do not operate the charger if it has been dropped received a sharp hit or otherwise damaged in any way For continued protection and to reduce the risk of fire install chargers on a floor of non combustible material such as stone brick or grounded metal WARNING The shipping pallet must be removed for proper and safe operation INSTRUCTIONS DE SECURITE IMPORTANTES Ce manuel contient des informations et des consignes importantes pour l emploi et l utilisation du chargeur de batteries industrielles Avant tout emploi il est forte
31. ing Multiple Floor Cabinet Chargers These chargers can be stacked up to a maximum of 3 units high Chargers are not designed to be stacked side by side due to ventilation requirements 1 Position the first charger so that a minimum of 6 inches of space is between the charger and any wall and 12 inches between the charger and any other chargers or equipment 2 Place the second charger on top of the first Align the bolt holes on each charger 3 Fasten both charger cabinets together securely using 3 8 bolts and nuts NOTE the two bolts toward the back of the charger may be omitted if an after market metal strap about 8 inches is used to secure both chargers Remove existing 1 4 screws of the chargers sides and attach strap with screws Refer to picture Hardware kit X225 99 0 2 can be ordered to attach two chargers 4 Repeat steps 2 and 3 for the third charger METAL STRAP Al 4 f 5 Stacked chargers must be fastened to the wall using devices suitable for the wall construction and the bolt holes at the top of TWO STACKED CHARGERS RIGHT SIDE VIEW the highest charger NOTE Ambient temperature at all levels cannot exceed 104 F 40 C Legacy Insight Service Manual 1 1621 Rev A 6 10 14 Electrical Connections To prevent failure of the charger be sure it is connected to the correct line voltage On three phase uni
32. ions check for defective cells Check that fans are working Verify that ambient temperature is not too YES high Inspect to see if charger ventilation is obstructed or impaired Critical battery electrolyte Make sure battery electrolyte is SERE level brought up to the proper level Barone f mpsrature reached Allow battery to cool Check max TEMP Yes 22 P temperature setting in Configuration gt Battery gt Max Temp DEF CFG DEF EEP Yes 2 Check configuration DEF MENU Low battery electrolyte Check battery electrolyte level Ex No Battery balance fault Check battery cell voltages mo No High battery temperature Allow battery to cool Battery may need service 23 Legacy Insight Service Manual 1 1621 Rev A 6 10 14 MAINTENANCE amp SERVICE CAUTION THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CHARGER CABINET ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO ADJUST OR SERVICE THIS BATTERY CHARGER The charger requires a minimum amount of maintenance Connections and terminals should be kept clean and tight The unit especially the heatsink should be periodically cleaned with an air hose to prevent any excessive dirt build up on components Care should be taken not to bump or move any adjustments during cleaning Make sure that both the AC lines and the battery are disconnected before cleaning The frequency of this type of maintenance depends on the e
33. ment conseill de lire l ensemble des instructions recommandations et avertissements concernant le chargeur et la batterie Ce chargeur a t concu pour la charge des batteries industrielles type plomb acide dite ouverte Il ne peut pas tre adapt pour les batteries tanches Lisez toutes les condisnes d installation et d utilisation avant d employer le chargeur de batterie pour emp cher des dommages la batterie et ou au chargeur Ne pas tre en contact avec les pi ces sous tension non isol es tels que la prise de charge ou des l ments de connexion de la batterie pour emp cher le choc lectrique Pendant la charge le d gagement d hydrog ne rend l emploi de feu strictement interdit risque d explosion Ne jamais fumer employer une flamme nue ou cr ez les tincelles proximit de la batterie Ventiler suffisamment pour viter toute condensation de gaz dans un espace restreint Ne brancher ou d brancher la batterie que si le chargeur est l arr t Faire ainsi risque d endommager la prise de charge pouvant avoir pour cons quence des dommages du chargeur ou l explosion de la batterie Les batteries d acide au plomb contiennent l acide sulfurique qui cause des br lures Eviter le contact avec les yeux la peau ou sur l habillement Dans le cas de contact avec les yeux et faut nettoyer imm diatement avec de l eau propre pendant 15 minutes et consulter un m decin imm diatement Seul le personnel qualifi par l
34. nvironment in which this unit is installed 24 Legacy Insight Service Manual 1 1621 Rev A 6 10 14 TESTING OF COMPONENTS ONLY QUALIFIED PERSONNEL SHOULD SERVICE THIS BATTERY CHARGER 1 INPUT FUSES Schematic symbol F1 F2 F3 Disconnect the AC power and the battery before opening the charger door This check is carried out using a multimeter set to the Q position at the lowest rating 0 Q fuse OK Infinity 2 replace the fuse Repeat the check for all the fuses 2 BRIDGE RECTIFIER AND IGBT MODULE Schematic symbol G1 bridge G2 IGBT Disconnect the AC Power and the battery before opening the charger door This check is made with the multimeter in the diode check position The test is run several stages to check without disconnecting the bridge rectifier Repeat this test when replacing an IGBT module an IGBT module that is bad can mask a failed bridge rectifier THE IGBT AND IF NEEDED BRIDGE RECTIFIER CONNECTION TIGHTENING TORQUE 26in lb THERMAL GREASE IS REQUIRED ON THE HEATSINK Test T Tet Reading Result erminals A 1102 207 V IGBT and Bridge Rectifier OK 1102 0 4V B 3 to 2 04V pus replace Bridge 1to3 0 4V 1102 0 4V 3 to 2 0 4V 1to3 z0 0V OR Replace IGBT repeat 1t02 0 4V_ this measurement after 3 to2 0 0V_ the IGBT replacement 1to3 0 4V Or 1to3 0 0 V 25 Legacy Insight Service Manual 1 1621 Rev A
35. oS ms Update Software Update chargers internal software The software is provided by EnerSys and only authorized service personnel should perform this function Eject For safe removal of the USB stick without damaging the data file Configuration This menu allows for configuration of the charger Password is required to view this menu Configuration access code is 0099 Access On the Main Menu select Configuration and then press ENTER With the charger at rest press ENTER On the first menu select CONFIGURATION and press ENTER Use the two and A pads to display the number corresponding to your password and confirm by pressing ENTER The main menu will come up To change the charge coefficient for the lonic Profile enter password Default 0099 press ENTER and set the coefficient Press ENTER and then lt ESC gt to exit Battery Auto Manu capacity When in lonic mode the charger can estimate the capacity of the connected battery automatically Auto or the charger will use the capacity entered manually Manu in the Capacity menu Legacy Insight Service Manual 1 1621 Rev A 6 10 14 Capacity Battery capacity used by the charger must be set to Manu for lonic profile to determine start and finish rates Temperature This parameter adjusts the regulation voltages on the charging profile values between 15 C 5 F and 65 C 149 F and defines the average operating bat
36. oth batteries are connected Legacy Insight Service Manual 1 1621 Rev A 6 10 14 GLOSSARY Charging Coefficient The ratio of the number of ampere hours restored during charging to the number of ampere hours consumed during discharge Charging Profile The charging profile defines the rate of current charge over time The charger adapts to the battery s age and level of discharge Controlling the overcharge coefficient whatever the battery s discharge level reduces the amount of electricity consumed Cold Storage This is a charging profile that allows the configuration of the charger for use with batteries in cold storage application The profile is an constant current constant voltage constant current type with a number of user configurable parameters Equalization Charging Equalization charging performed after normal charging balances the electrolyte densities in the battery s cells IGBT The IGBT controls the charger output by rapidly switching the transformer primary at 20 to 30 kHz lonic Profile Also called ionic mixing This type of charging profile consists of sending short pulses of current to stimulate gas formation in the active material causing sulfuric acid to be distributed outside the plates This system of mixing the electrolyte enables more rapid charging of flooded cell batteries subject to very high demands and balances out differences in density homogenizing the electroly
37. r charging CEC Describes that the chargers are certified by the California Energy Commission Legacy Insight Service Manual I B 1621 Rev A 6 10 14 OPERATING INSTRUCTIONS The Legacy Insight series of chargers are compatible with batteries at 12 24 36 48 72 and 80 volts depending on the version supplied These chargers can automatically recharge batteries in the following ranges 12 24 36V 24 36 48V and 48 72V or 48 80V Note 72V or 80V is selected by switching jumpers on the control board See chart and illustration below Battery recognition voltage capacity and state of charge is accomplished automatically by the microprocessor Several charging profiles are available Cold Storage IONIC Opportunity VRLA based on the configuration chosen by the operator Furthermore equalization and compensation charges are integrated V Jumper Jumper Charger Output 6 12 10KW 48V 72V 6 11 10KW 48V 80V 6 15 15KW 48V 72V 6 14 15KW 48V 80V EQ3 Jumper Identification jumper popes a ee eee ee 11 Legacy Insight Service Manual I B 1621 Rev A 6 10 14 Control Panel DOUGLAS EGA C Y INSIGHT 1 e FAULT 3 2 6 4 5 Ref Function Description 1 Graphical LCD Display Display charger operation info Menus 2 Navigate UP button Navigate menus Change values ENTER STOP amp ST
38. r of Cells Input Volt code Options D C AMPS MAX Serial Number This number indicates complete information about the specific charger It must be supplied with the part number on any correspondence or discussion regarding this charger Battery Type The chemical content construction of the battery this unit is designed to charge is given in this part of the nameplate L A Lead Acid Ampere Hours The information supplied here is the maximum ampere hours capacity of this charger Charging batteries of ampere hour capacities not specified here might cause the charger to deviate from the specifications Cells This portion of the nameplate gives the number of cells this unit will charge This number must match exactly with any battery connected to the charger output Input AC Volts The nameplate shows the input voltage accommodated by this charger IMPORTANT The charger will operate only on nominal line voltages stamped on the nameplate Failure to select the correct voltage will result in damage to the charger and or the battery Input AC Amps The external fusing and or the line disconnect circuit breaker should be as specified in the National Electrical Code or other local code agencies AC fuse values can be found on the decal inside the charger Legacy Insight Service Manual 1 1621 Rev A 6 10 14 Hz This gives the frequency in cycles per second of the AC input voltage Under no conditions operate charger
39. s bar that ties all the diodes together you may loosen the buss bar and try sliding the damaged diode out Unscrew the main transformer lead and remove the small buss bar from the damaged diode and install it on the new diode REPLACEMENT Surface must be free of scratches gouges or burrs No oil dirt paint adhesive or other foreign substances are permitted in the contact area Apply a light coating of heat sink thermal compound to the flat metal side of the IGBT Bridge Rectifier or Diode Tighten the mounting screws with your fingers as far as possible Then use the torque wrench set as follows for mounting and terminal screws IGBTs etes 26in Ib Bridge Rectifier 26in Ib Diodes 11in Ib Install back all components removed in reversed order PC BOARD REMOVAL CAUTION Use an anti static wrist strap when removing and replacing circuit board assemblies Please follow these steps to remove a PC board Be sure your hands are clean before touching a PC board 1 Turn the AC power OFF and disconnect the battery 2 Touch your finger to a ground to remove any static charge 3 Unplug all connectors from the PC board Some connectors may be secured by screws 4 Pullthe board out from its mounting standoffs NOTE Handle the PC board with care Do NOT place it on top of the battery or other acid contaminated surfaces 5 Place the removed PC board into the anti static bag or foam that the replacement bo
40. te across the surface of the plates Legacy Insight Service Manual 1 1621 Rev A 6 10 14 OPPOR Profile The OPPOR charge profile is used when opportunity charging is desired It has a start rate of 25 of the batteries rated amp hour capacity requires one opportunity recharge in every 24 hours of service and must have an equalize charge done once a week which is programmed to run automatically Operation During opportunity charging the user can plug the battery in and charge it during breaks lunch or any work stoppage time Sufficient time should be scheduled after the full charge to allow the battery to completely cool to ambient temperatures before use Daily Charge When Profile is set to Opp the Value programmed will be the time of day for a Complete lonic charge Type is ignored when Profile is set to Opp One complete lonic charge per day is recommended Note The user must configure the charger for the time of day that the full recharge is to take place they must also configure the day of the week that the equalize charge will take place Power Diodes The power diodes rectify the AC input and the output of the transformer Refresh Charging Refresh or maintenance charging enables the battery to be maintained at maximum charge all the time that it is connected to the charger Rest Function The Rest function prevents the battery from being disconnected for a pre defined period to ensure a period of inactivity afte
41. tery temperature before the charge It is recommended the average electrolyte temperature be entered especially in cold areas Charge Profile For selecting the right charging profile for the application COLD STORE IONIC OPP VRLA The profile selected will be used Values stored in the BATTERY menu such as CAPACITY except lonic and TEMPERATURE are used to determine key charging parameters Make sure these values match the battery to be charged or the battery may be over or under charged which will result in decreased battery life or performance Charge Delay Under Type choices are either OFF DELAY or TIME OF DAY VALUE is the amount or time day for the delay 00 00 to 24 00 Delay Start of charge is delayed for the amount of time stored in VALUE 0 to 24 hours Time of Day Charge will not start until the time of day stored in VALUE 24 hour format Daily Charge If charger profile is set to OPP one complete lonic charge per day is recommended Enough down time should be allowed so the battery can remain plugged in to receive a full charge Typically 4 to 5 hours depending on the state of discharge As long as the battery is plugged in between the start time and the end time it will finish if allowed to do so Daily Chg Start Start time for complete charge 24 hour format factory default if not specified 22 00 Daily Chg End End time for complete charge If charger is plugged in after this time it will revert back to oppor
42. ts Connect all chargers as follows Phase A to L1 fuse block Phase B to L2 fuse block Phase C to L3 fuse block Connecting Input Power WARNING Make sure the power to the charger is OFF and the battery is disconnected before connecting the input power to the terminals of the charger Connect the input power to the appropriate terminals including ground Follow your local electrical or National Electric Code in making these connections AC Connection The user must provide suitable branch circuit protection and a disconnect method from the AC power supply to the charger to allow for safe servicing Plug Polarity The charging cable is connected to the DC output of the charger with the positive lead marked RED The output polarity of the charger must be strictly observed when connecting to the battery read warning above Improper connection will open the DC fuse Grounding the Charger DANGER FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC SHOCK Follow National Electric Code for ground wire sizing Connect a grounding conductor to the lug provided on the horizontal support panel This lug is marked as shown Legacy Insight Service Manual 1 1621 Rev A 6 10 14 DESCRIPTION OF OPERATION General Legacy Insight chargers are microprocessor controlled The processor calculates the battery s capacity so that the charging profile can be automatically adapted to the battery s actual state over a
43. tunity charging 24 hour format factory default if not specified 4 00 Daily Chg On Off Sets the complete daily charge on or off Condition charge The charger will only commence the charge if the battery has reached the limit of depth of discharge DoD of more than x95 For example if the user wants to charge the battery only if itis discharged more than 3096 the parameter 30 has to be entered in the conditional charge The 0 value disables the function Legacy Insight Service Manual 1 1621 Rev A 6 10 14 Float Charge This feature can be turned ON or OFF depending on the application A float charge at the end of standard charge is intended to compensate for consumption by the truck electronics that are left on when truck is not used typically AGV The parameter VOLTAGE is in mVpc millivolts per cell determines the maximum float voltage The parameter CURRENT defines the current output during float the current will automatically decrease to keep the battery voltage at the maximum defined by the VOLTAGE parameter Maximum current This manually decreases the maximum output current of the charger Equalization Manu Current This defines the equalization or desulphation current for a manual start Manual Equalization is disabled during Opportunity cycles Time Sets the equalization time from 1 to 48 hrs Delayed start delay Sets the delay between the normal charge and the equalization charge from 0 hr to 23 hrs
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