Table of Contents
Related Manuals for Legacy Insight Standard LI3
Summary of Contents for Legacy Insight Standard LI3
- Page 1 Model: Standard LI3 & LI3C (CEC) Legacy Insight™ Battery Charger ® Service Manual I.B. 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...
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Page 2: Table Of Contents
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy TABLE OF CONTENTS AC Line Voltage Letter Codes ....2 Record Memo ........16 Specialty Charger Option List ....2 Update Software ....... 16 Configuration ......... 16 Important Safety Instructions ..... 3 Battery .......... -
Page 3: Legacy ® Insight
Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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. -
Page 4: Important Safety Instructions
Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy IMPORTANT SAFETY INSTRUCTIONS 1. 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. -
Page 5: Technical Information
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy TECHNICAL INFORMATION The nameplate, located on the outside of the charger, should be used to check this application before installation. Part Number This number specifies in general the characteristics of this particular charger and for this reason it is required in any discussion or correspondence regarding this unit. -
Page 6: Phase
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy This gives the frequency in cycles per second of the AC input voltage. Under no conditions operate charger at a different frequency or from a generator with unstable frequency. Phase Number "3" indicates a Three Phase Charger. -
Page 7: Installation
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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. -
Page 8: Electrical Connections
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy Electrical Connections To prevent failure of the charger, be sure it is connected to the correct line voltage. On three phase units Connect all chargers as follows: Phase A to L1 (fuse block) -
Page 9: Description Of Operation
The charging coefficient is maintained absolutely ® on all types of batteries. Legacy Insight™ chargers adapt to the battery’s capacity and its discharge level. -
Page 10: Glossary
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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. -
Page 11: Oppor Profile
Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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. -
Page 12: Operating Instructions
Legacy 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*. - Page 13 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy Control Panel Ref. Function Description Graphical LCD Display. Display charger operation info/Menus Navigate UP button Navigate menus/Change values ENTER/STOP&START button Select menu items/Enter values/Stop and restart battery charge Navigate RIGHT/EQUALIZE button...
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Page 14: Menu Access
Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy Menu Access When the charger is idle, press and hold <ESC>, 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 <ESC>... -
Page 15: Status
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy Displaying a charge cycle Proceed as follows: 1. Select a record (MEMO x) using the ▲/▼ buttons. 2. Display the first History screen by pressing Enter. 3. Display the second History screen by pressing▼. -
Page 16: Usb
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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). -
Page 17: Capacity
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy Capacity Battery capacity used by the charger (must be set to “Manu” for Ionic 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 battery temperature before the... -
Page 18: Float Charge
Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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). -
Page 19: Rst Memo/Status
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy Rst Memo/Status Resets and clears all memorizations and status history. WARNING! ONCE THE MEMORIZATIONS AND STATUS HAVE BEEN CLEARED THEY CANNOT BE RECOVERED! -
Page 20: Parameters
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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 ahead 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. -
Page 21: Charging The Battery
Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy Charging the Battery 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. -
Page 22: Starting A Charge Cycle
Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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. - Page 23 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy End of charge without equalization The green complete LED comes on after proper end of charge. The green complete LED is on and the display shows AVAIL. The display alternates between: ...
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Page 24: Fault Codes
Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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. -
Page 25: Maintenance & Service
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy MAINTENANCE & SERVICE THERE ARE DANGEROUS VOLTAGES WITHIN THE BATTERY CAUTION: 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. -
Page 26: Testing Of Components
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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. - Page 27 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy DC OUTPUT FUSE Schematic symbol: F3 Disconnect the AC power and the battery before opening the door. Ω The checking of output fuse F3 is carried out with the multimeter in position.
- Page 28 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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.
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Page 29: Component Replacement
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy 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. -
Page 30: Wall Mounting Dimensions
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy WALL MOUNTING DIMENSIONS 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... -
Page 31: Exterior Wall Cabinet Dimensions
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy EXTERIOR WALL CABINET DIMENSIONS AND PARTS 009-IQ-1 009-IQ-4 Kit P/N: X225-019-IQ-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. -
Page 32: Floor Mounting Dimensions
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy FLOOR MOUNTING DIMENSIONS FRONT BACK... -
Page 33: Exterior Floor Cabinet Dimensions
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy EXTERIOR FLOOR CABINET DIMENSIONS AND PARTS Top P/N: X052-99-3-12B Left Side P/N: X057-99-0-7B Door P/N: X054-99-3-17B Right Side P/N: X057-99-0-6B Back P/N: X057-99-3-16B... -
Page 34: Technical Specifications
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy TECHNICAL SPECIFICATIONS KW - Output AC Input DC Output Max 8 hour Charger Voltage Codes Voltage Phase Cells Max Current Capacity (Ah) Cable Amps 4-1T 12.4 12/18/24 85/80/70 530/500/400 4-1W 11.4... - Page 35 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy REPLACEMENT PARTS and QUANTITY Part Number Description X1060-IQ4-1T3 Control Board X1060-IQ4-1W3 Control Board X1060-IQ4-1Y3 Control Board X1060-IQ4-1C3 Control Board X1060-IQ4-3T3 Control Board X1060-IQ4-3W3 Control Board X1060-IQ4-3Y3 Control Board X1060-IQ4-3C3 Control Board...
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Page 36: Replacement Parts
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy REPLACEMENT PARTS and QUANTITY Part Number Description X026-EQ3-1 Display Board X1060-12-SB208 208V Power Board X1060- 240V Power Board 6LA11713 X1060- 480V Power Board 6LA11662 X1060- 600V Power Board 6LA11722 X127-6LA10659 Power Transformer... - Page 37 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy REPLACEMENT PARTS and QUANTITY Part Number Description R507-6LA14008 Output Diode R507-6L14028 Output Diode R507-6L14022 Bridge Rectifier X020-6L18616 Line Choke X020-6L10310 Line Choke X020-6LA10334 Resonant Choke X020-6LA10323 Resonant Choke X020-6LA18621 Resonant Choke...
- Page 38 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy REPLACEMENT PARTS and QUANTITY Part Number Description X020-6L-3 AC Power Line Filter X020-6L-4 AC Power Line Filter 126-EQ3-1 Display Ribbon Cable X026-60-1 Control BD Ret. Clip X1106-99-PT23 Current Sensor 438-326-2 Cooling Fan...
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Page 39: Component Locations
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy LARGE WALL CHARGER COMPONENT LOCATIONS AC Fuse Block AC Fuse Display Board Keypad Bridge Rectifier AC Power Line Filter Bridge MOV 090-6LA20311 Resonant Choke 090-6LA20403 090-IQ-1 Line Choke 10uF Capacitors Resonant Capacitors... - Page 40 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy SMALL WALL CHARGER COMPONENT LOCATIONS Keypad AC Fuse Block AC Fuse Display Board AC Power Line Filter Bridge MOV Resonant Choke Bridge Rectifier 090-6L20135 Power Board Line Choke 090-11-4 Resonant Capacitors...
- Page 41 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy FLOOR CHARGER LARGE CONFIGURATION COMPONENT LOCATIONS 090-6LA20403 090-6LA20436 Bridge Rectifier Bridge MOV AC Fuse Block 10uF Capacitors Resonant Capacitors AC Fuse Line Choke Power Transformer Power Board 090-6LA20311 Resonant Choke Current Sensor...
- Page 42 ® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy FLOOR CHARGER SMALL CONFIGURATION COMPONENT LOCATIONS 10uF Capacitors Bridge Rectifier 090-11-4 090-6L20135 Bridge MOV AC Fuse Block Resonant Capacitors Line Choke AC Fuse Power Transformer Power Board 090-11-3 Resonant Choke Current Sensor...
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Page 43: Schematic
® Insight™ Service Manual I.B. 1621 Rev.A (6/10/14) Legacy N/A FOR CEC SCHEMATIC CHARGERS... - Page 44 1255 Creekshire Way, Suite 221, Winston-Salem, NC 27103 1-800-DOUGLAS (1-800-368-4527) www.douglasbattery.com I.B. 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.